The Analysis of Process Parameters for Turning Cobalt-Based Super Alloy Haynes 25 / L 605 Using Design of Experiment

2015 ◽  
Vol 220-221 ◽  
pp. 749-753 ◽  
Author(s):  
Murat Sarikaya ◽  
Abdulkadir Güllü
Keyword(s):  
Surface Roughness ◽  
Design Of Experiment ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cooling Condition ◽  
Machining Parameters ◽  
Dry Cutting ◽  
Power Generators ◽  
Arithmetic Average ◽  
Super Alloy

Haynes-25 alloy (also known as L-605 alloy) is extensively used in the applications of aerospace industry, turbine and furnace parts, power generators and heat exchangers and petroleum refining components due to its excellent properties. However, machining this alloy is more difficult compared to normal steel or even stainless one because of its characteristics of hardness and strength. This paper presents experimental investigation into machining parameters in the turning process of Haynes 25 alloy using uncoated carbide tools. Design of experiment (DOE) has been used for studying the effect of the main turning parameters such as cooling condition, cutting speed and feed rate on the arithmetic average surface roughness (Ra) of Haynes-25 alloy. Tests are designed according to Taguchi’s orthogonal array. Experiments have been performed under dry cutting and conventional wet cooling. Minimum surface roughness was obtained in turning using uncoated tools under wet cooling condition at the cutting speed of 45 m/min and feed rate of 0.12 mm/rev.

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.

In Situ: A Novel Approach for the Production of Micro Holes

2010 ◽  
Vol 126-128 ◽  
pp. 885-890
Author(s):  
K.P. Somashekhar ◽  
N. Ramachandran ◽  
Jose Mathew
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
Machining Parameters ◽  
Average Roughness ◽  
Arithmetic Average ◽  
Quantitative Correlation ◽  
Good Surface ◽  
Novel Approach ◽  
Micro Holes

This work is on the preparation of microelectrodes for μ-EDM operation using μ-WEDG process. Electrodes of Ø500 μm are fabricated with various discharge energy machining conditions. Effects of gap voltage, capacitance & feed rate on the surface finish of the electrodes and overcut of the thus produced micro holes are investigated. The profile of microelectrodes is measured using surface roughness tester with 2μm stylus interfaced with SURFPAK software. The study demonstrated that for brass electrodes an arithmetic average roughness value as low as 1.7μm and an overcut of 3 µm could be achieved. The significant machining parameters are found using ANOVA. Surface of the produced microelectrodes are examined using Scanning Electron Microscope. μ-WEDG process parameters could be adjusted to achieve good surface integrity on microelectrodes. Experimental results showed that the surface roughness of microelectrodes depended primarily on feed rate of the electrode. The observations showed the clear and quantitative correlation existing between the micrometer level surface quality and process parameters. The resulting microelectrodes are found to be of exceptionally high quality and could be used for μ- EDM operation on different types of work materials.

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.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

scholarly journals Analysis and Optimization of Cutting Tool Coating Effects on Surface Roughness and Cutting Forces on Turning of AA 6061 Alloy

2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
Mahir Akgün ◽  
Fuat Kara
Keyword(s):  
Surface Roughness ◽  
Mathematical Models ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Machined Surface ◽  
Tool Coating ◽  
Cutting Inserts

The present work has been focused on cutting force (Fc) and analysis of machined surface in turning of AA 6061 alloy with uncoated and PVD-TiB2 coated cutting inserts. Turning tests have been conducted on a CNC turning under dry cutting conditions based on Taguchi L18 (21 × 33) array. Kistler 9257A type dynamometer and equipment have been used in measuring the main cutting force (Fc) in turning experiments. Analysis of variance (ANOVA) has been applied to define the effect levels of the turning parameters on Fc and Ra. Moreover, the mathematical models for Fc and Ra have been developed via linear and quadratic regression models. The results indicated that the best performance in terms of Fc and Ra was obtained at an uncoated insert, cutting speed of 350 m/min, feed rate of 0.1 mm/rev, and depth of cut of 1 mm. Moreover, the feed rate is the most influential parameter on Ra and Fc, with 64.28% and 54.9%, respectively. The developed mathematical models for cutting force (Fc) and surface roughness (Ra) present reliable results with coefficients of determination (R2) of 96.04% and 92.15%, respectively.

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.

Investigations on the Effect of CNC Dry Hard Turning Process Parameters on Surface Integrity: A Multi-performance Characteristics Optimization

2014 ◽  
Vol 14 (1) ◽  
pp. 23-30 ◽  
Author(s):  
Suha K. Shihab ◽  
Zahid A. Khan ◽  
Aas Mohammad ◽  
Arshad Noor Siddiquee
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Influential Factor ◽  
Depth Of Cut ◽  
Micro Hardness ◽  
Dry Cutting

AbstractThe cutting parameters such as the cutting speed, the feed rate, the depth of cut, etc. are expected to affect the two constituents of surface integrity (SI), i.e., surface roughness and micro-hardness. An attempt has been made in this paper to investigate the effect of the CNC hard turning parameters on the surface roughness average (Ra) and the micro-hardness (μh) of AISI 52100 hard steel under dry cutting conditions. Nine experimental runs based on an orthogonal array of the Taguchi method were performed and grey relational analysis method was subsequently applied to determine an optimal cutting parameter setting. The feed rate was found to be the most influential factor for both the Ra and the μh. Further, the results of the analysis of variance (ANOVA) revealed that the cutting speed is the most significant controlled factor for affecting the SI in the turning operation according to the weighted sum grade of the surface roughness average and micro-hardness.

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