Effect of SiC Particles on the Machining of Aluminum/SiC Composite

2009 ◽  
Vol 626-627 ◽  
pp. 219-224 ◽  
Author(s):  
Gao Feng Zhang ◽  
Yuan Qiang Tan ◽  
Bi Zhang ◽  
Zhao Hui Deng
Keyword(s):  
Surface Roughness ◽  
Aluminum Matrix ◽  
Volume Ratio ◽  
Damage Mechanism ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Aluminum Metal ◽  
Sic Particles ◽  
Average Grain Size

The objective of this study is to experimentally investigate the effect of reinforced SiC particles on the machining of Aluminum/SiC composite (15% volume ratio of SiC particles with average grain size 15m). Aluminum/SiC composite and aluminum metal were milled by a tungsten carbide endmill in this study. Based on the surface observation and surface roughness inspection, it is found that the machining parameters of Aluminum/SiC composite have optimum values, and that the surface roughness of aluminum/SiC composite is smaller than that of aluminum metal. when feedrate and depth of cut are smaller than limited values, satisfactory surface finish can be attainable, however, as the depth of cut and feedrate increases, the microcracks are first initiated at the interface of SiC particles and aluminum matrix, and then periodically macrocracks are formed on the machined surface, The damage mechanism during the machining of aluminum/SiC are discussed in this paper.

Multi Objective Optimization of Cutting Parameters in Machining Cellulose Based Hybrid Composites

2015 ◽  
Vol 761 ◽  
pp. 287-292
Author(s):  
Raja Izamshah ◽  
Zainudin Zuraidah ◽  
Mohd Shahir Kasim ◽  
M. Hadzley ◽  
M. Amran
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hybrid Composites ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Multi Objective Optimization ◽  
Machining Performance ◽  
Machined Surface ◽  
Multi Objective ◽  
Optimization Of Cutting Parameters

Cellulose based hybrid composites are gaining popularity in the growing green communities. With extensive studies and increasing applications for future advancement, the need for an accurate and reliable guidance in machining this type of composites has increased enormously. Smooth and defect free machined surface are always the ultimate objectives. The present work deals with the study of machining parameters (i.e. spindle speed, feed rate and depth of cut) and their effects on machining performance (i.e. surface roughness and delamination) to establish an optimized setup of machining parameters in achieving multi objective machining performance. Cellulose based hybrid composites consist of jute (a bast fiber) and glass fiber embedded in polyester resins. Response Surface Methodology (RSM) using Box-Behnken Design (BBD) was chosen as the design of experiment approach for this study. Based on that experimental approach, 17 experimental runs were conducted. Mathematical model for each response was developed based on the experimental data. Adequacy of the models were analyzed statistically using Analysis of Variance (ANOVA) in determining the significant input variables and possible interactions. The multi objective optimization was performed through numerical optimization, and the predicted results were validated. The agreement between the experimental and selected solution was found to be strong, between 95% to 96%, thus validating the solution as the optimal machining condition. The findings suggest that feed rate was the main factor affecting surface roughness and delamination .

An Investigation about the Effect of Depth of Cut on Surface Integrity in Creep Feed Grinding of INC 792-5A

2011 ◽  
Vol 320 ◽  
pp. 163-169
Author(s):  
R. Ashofteh ◽  
A. Rastkerdar ◽  
S. Kolahdouz ◽  
A. Daneshi
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Structural Changes ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cutting Depth ◽  
Creep Feed Grinding ◽  
Creep Feed ◽  
Micro Cracks ◽  
Average Grain Size

Creep-Feed Grinding(CFG) is one of the none-traditional machining in which form grinding to full depth is performed in limited number of passes. One of the most significant criteria which is taken into account to display valid machining parameters, is surface integrity. Surface integrity in CFG process is influenced by four main factors including surface roughness, superficial micro-crack, burning and changes in micro-hardness. According to prior investigations in CFG process, depth of cut plays an important role in surface integrity. In this study, the influence of cutting depth on workpiece surface integrity of cast nickel-based superalloy with alummina wheels, was investigated. During this study, a sample part was machined with variable depth of cut while the other parameters were Constant. After machining, surface roughness of each specimen was measured and in order to investigate existence and dimensional situation of surface micro-cracks, Chemical Etch + FPI and Thermal shock + FPI were performed. For determining micro-structural changes in ground specimens as a clarifier criteria in measuring the level of residual stress, a set of recrystallization processes were carried out on them and average grain size were measured. The results show, however, changing in depth of cut hasn't influenced on micro-cracks, quality of surface roughness has descended in terms of increasing the cutting depth.

scholarly journals Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

2020 ◽  
pp. 095440542097666
Author(s):  
Trung-Thanh Nguyen ◽  
Chi-Hieu Le
Keyword(s):  
Surface Roughness ◽  
Energy Consumption ◽  
Surface Hardness ◽  
Compressed Air ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machining Quality ◽  
Machining Speed ◽  
Burnishing Process

The burnishing process is used to enhance the machining quality via improving the surface finish, surface hardness, wear-resistance, fatigue, and corrosion resistance, and it is mostly used in aerospace, biomedical, and automotive industries to improve reliability and performance of the component. The combined turning and burnishing process is therefore considered as an effective solution to enhance both machining quality and productivity. However, the trade-off analysis between energy consumption, surface characteristics, and production costs has not been well-addressed and investigated. This study presents an optimization of the compressed air assisted-turning-burnishing (CATB) process for aluminum alloy 6061, aimed to decrease the energy consumption as well as surface roughness and to enhance the Vicker hardness of the machined surface. The machining parameters for consideration include the machining speed, feed rate, depth of cut, burnishing force, and the ball diameter. The improved Kriging models were used to construct the relations between machining parameters and the technological response characteristics of the machined surface. The optimal machining parameters were obtained utilizing the desirability approach. The energy based-cost model was developed to assess the effectiveness of the proposed CATB process. The findings showed that the selected optimal outcomes of the depth of cut, burnishing force, diameter, feed rate, and machining speed are 0.66 mm, 196.3 N, 8.0 mm, 0.112 mm/rev, and 110.0 m/min, respectively. The energy consumption and surface roughness are decreased by 20.15% and 65.38%, respectively, while the surface hardness is improved by 30.05%. The production cost is decreased by 17.19% at the optimal solution. Finally, the proposed CATB process shows a great potential to replace the traditional techniques which are used to machine non-ferrous metals.

scholarly journals On the Effect of Electron Beam Melted Ti6Al4V Part Orientations during Milling

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1172
Author(s):  
Abdulmajeed Dabwan ◽  
Saqib Anwar ◽  
Ali M. Al-Samhan ◽  
Mustafa M. Nasr
Keyword(s):  
Surface Roughness ◽  
Electron Beam ◽  
Surface Morphology ◽  
Surface Quality ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Radial Depth

The machining of the electron beam melting (EBM) produced parts is a challenging task because, upon machining, different part orientations (EBM layers’ orientations) produce different surface quality even when the same machining parameters are employed. In this paper, the EBM fabricated parts are machined in three possible orientations with regard to the tool feed direction, where the three orientations are “tool movement in a layer plane” (TILP), “tool movement perpendicular to layer planes” (TLP), and “tool movement parallel to layers planes” (TPLP). The influence of the feed rate, radial depth of cut, and cutting speed is studied on surface roughness, cutting force, micro-hardness, microstructure, chip morphology, and surface morphology of Ti6Al4V, while considering the EBM part orientations. It was found that different orientations have different effects on the machined surface during milling. The results show that the EBM parts can achieve good surface quality and surface integrity when milled along the TLP orientation. For instance, surface roughness (Sa) can be improved up to 29% when the milling tool is fed along the TLP orientation compared to the other orientations (TILP and TPLP). Furthermore, surface morphology significantly improves with lower micro-pits, redeposited chips, and feed marks in case of the TLP orientation.

Experimental Study on Milling Hardened SKD Steel Using Micro CBN Ball-End Mills

2010 ◽  
Vol 126-128 ◽  
pp. 773-778
Author(s):  
Yung Tien Liu ◽  
Neng Hsin Chiu ◽  
Yen Chun Lin ◽  
Chih Liang Lai ◽  
Yu Fu Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Machined Surface ◽  
Performance Function ◽  
End Mills

Micro ball-end milling process features the ability of machining complex surfaces, precision machining accuracy, and excellent machined surface roughness. However, because the diameter of a micro milling tool is very small, a rapid progress of tool wear or even tool breakage usually happens when machining a high-strength hardened mold steel using improper machining parameters. As a result, the machining cost would rise due to the quality defect in machined workpiece. In this study, to investigate how the machining parameters affect the cutting behaviors, a series of experiments using micro CBN ball-end mills with a diameter of 0.5 mm were performed to cut the SKD11 mold steel with hardness of HRC 61. The machining parameters are selected as the feeding speed (f) being 840, 960 and 1,080 mm/min, depth of cut (ap) being 30, 45, 60 μm, and spindle speed (vs) being fixed as 30,000 rpm. According to the experimental results, the measured three-axis cutting forces, flank wears, and surface roughness of machined workpiece are highly related to the cutting length. It is expected that the measured results can be used to construct a performance function of a micro ball-end tool. With referring to the performance function, the tool life can be well expected, and thus a progress in machining efficiency without tool failure can be achieved.

scholarly journals Molecular Dynamics Investigation of Residual Stress and Surface Roughness of Cerium under Diamond Cutting

Micromachines ◽  
2018 ◽  
Vol 9 (8) ◽  
pp. 386 ◽  
Author(s):  
Yao Li ◽  
Maobing Shuai ◽  
Junjie Zhang ◽  
Haibing Zheng ◽  
Tao Sun ◽  
...  
Keyword(s):  
Molecular Dynamics ◽  
Residual Stress ◽  
Surface Roughness ◽  
Surface Quality ◽  
Depth Of Cut ◽  
Formation Mechanisms ◽  
Machining Parameters ◽  
Diamond Cutting ◽  
Machined Surface ◽  
Machined Surface Quality

Machined surface quality in terms of residual stress and surface roughness has an important influence on the performance of devices and components. In the present work, we elucidate the formation mechanisms of residual stress and surface roughness of single crystalline cerium under ultraprecision diamond cutting by means of molecular dynamics simulations. Influences of machining parameters, such as the rake angle of a cutting tool, depth of cut, and crystal orientation of the workpiece on the machined surface quality were also investigated. Simulation results revealed that dislocation activity and lattice distortion are the two parallel factors that govern the formation of both residual stress and surface roughness. It was found that both distributions of residual stress and surface roughness of machined surface are significantly affected by machining parameters. The optimum machining parameters for achieving high machined surface quality of cerium by diamond cutting are revealed.

Optimization of Milling Parameter for Untreated and Heat Treated Polyetheretherketones (PEEK) Biomaterials

2015 ◽  
Vol 761 ◽  
pp. 293-297
Author(s):  
Raja Izamshah ◽  
A. Yu Lung ◽  
Effendi Mohamad ◽  
Mohd Asyadi Azam ◽  
Mohd Amri ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Heat Treated ◽  
Machining Parameter

Polyetheretherketones (PEEK) have been widely used as biomaterials for trauma, orthopedics and spinal implants. However, machining of this material poses several challenges such as rough machined surface which can affect the implant functional application. This research attempts to optimize the machining parameter (cutting speed, feed rate and depth of cut) for effectively machining Polyetheretherketones (PEEK) implant material using carbide cutting tools. Apart from optimizing machining parameters, effects of annealing condition on PEEK towards surface qualities are discuss. Response Surface Methodology (RSM) technique was used to evaluate the effects of the parameters and their interaction towards the ability of the optimum conditions. Based on the analysis results, the optimal machining parameter to obtain the smallest surface roughness values were by using spindle speed of 5754 rpm, feed rate of 0.026 mm/tooth and 5.11 mm depth of cut for un-annealed PEEK. As for the annealed PEEK to get the smallest surface roughness values were by using spindle speed of 5865 rpm, feed rate of 0.025 mm/tooth and 2 mm depth of cut.

Surface Roughness Model for High Speed End Milling of Soda Lime Glass Using Carbide Coated Tools with Compressed Air Blowing

2012 ◽  
Vol 576 ◽  
pp. 107-110
Author(s):  
M.A. Mahmud ◽  
A.K.M. Nurul Amin ◽  
Muammer Din Arif
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Gas Turbines ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Machining Parameters ◽  
Machined Surface

Glass materials play a vital role in advancement of science and technology. They have found wide spread application in the industry, in laboratory equipment and in micro-gas turbines. Due to their low fracture toughness they are very difficult to machine, moreover there are the chip depositions on the machined surface which affects surface finish under ductile mode cutting conditions. In this research, high speed end milling of soda lime glass is performed on CNC vertical milling machine to investigate the effects of machining parameters i.e. spindle speed, depth of cut, and feed rate on machined surface roughness. Design of experiments was performed following Central Composite Design (CCD) of Response Surface Methodology (RSM). Design Expert Software was used for generating the empirical mathematical model for average surface roughness. The model’s validity was tested to 95% confidence level by Analysis of Variance (ANOVA). Subsequent experimental results showed that the developed mathematical model could successfully describe the performance indicators, i.e. surface roughness, within the controlled limits of the factors that were considered.

Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

2016 ◽  
Author(s):  
Issam Abu-Mahfouz ◽  
Amit Banerjee ◽  
A. H. M. Esfakur Rahman
Keyword(s):  
Surface Roughness ◽  
Fuzzy Clustering ◽  
Wavelet Transforms ◽  
Fourier Transforms ◽  
End Milling ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machined Surface ◽  
Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

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