Comparative Analysis between Conventional and Dry Turning

2017 ◽  
Vol 261 ◽  
pp. 267-274
Author(s):  
Pantelis N. Botsaris ◽  
Chaido Kyritsi ◽  
Dimitris Iliadis
Keyword(s):  
Experimental Data ◽  
Surface Roughness ◽  
Cutting Tool ◽  
Spindle Motor ◽  
Air Cooling ◽  
Machining Parameters ◽  
Turning Process ◽  
Dry Cutting ◽  
Cold Air ◽  
Cooling And Lubrication

In this paper, there is an attempt to monitor and evaluate machining parameters when turning 34CrNiMo6 material under different cooling and lubrication conditions. The machining parameters concerned are temperature of the cutting tool and the workpiece, level of vibrations of the cutting tool, surface roughness of the workpiece, noise levels of the turning process and current drawn by the main spindle motor. Four different experimental machining scenarios were completed, specifically: conventional wet turning process, dry cutting and two additional modes employing cooling by cold air. Experimental data were acquired and recorded by an optimally designed network of sensors. Experimental data were statistically analyzed in order to reach conclusions. According to the research that has been done, although, overall, minimum cutting tool and workpiece temperatures were observed under wet machining, cold air cooling is capable of achieving comparable cooling results to wet machining. The lowest values of surface roughness were achieved by wet machining, whereas the lowest level of cutting tool vibrations were observed under cold air cooling.

Machining Parameters Evaluation During a Wet, Lubricated, and Air-cooled Turning Process

2014 ◽  
Vol 14 (1) ◽  
pp. 47-58
Author(s):  
Pantelis N. Botsaris ◽  
Efstratios L. Ntantis
Keyword(s):  
Surface Roughness ◽  
Life Cycle ◽  
Cutting Tools ◽  
Machining Process ◽  
Machining Parameters ◽  
Turning Process ◽  
Dry Cutting ◽  
Nickel Chromium ◽  
Interesting Approach ◽  
Research Findings

AbstractIn this paper, there is an attempt to derive an observation and study of specific machining parameters after turning process of a DIN 34CrNiMo6 nickel-chromium stainless steel in a conventional center (lathe). The machining parameters concerned are the temperatures developed on cutting tools and the workpiece, the surface roughness of the workpiece after process, the level of vibrations of cutting tool, the noise levels of the process, and the current of the lathe motor. Four different experimental scenarios completed namely wet, dry and air-cooled process. An optimally designed sensor network installed to monitor and record the measurements of the examined machining parameters. The experimental data considered for examination with statistical analysis of developed charts which presented interesting research findings. In dry cutting, the machining temperatures and the amount of removed material, observed with the highest values among other experimental scenarios. The surface roughness found its smallest value after the end of the lubricated cutting and the machining process with minimum vibrations observed during the operation of the Airgun. However, the study also brought out an interesting and useful observation for future consideration in the area of a Life Cycle Assessment. The chips taken at the end of experimental scenarios will be used for an LCA analysis in relation to the initial material and machining process. This will give an opportunity of an interesting approach that can be applied to assess the environmental impacts throughout a product's life cycle.

Analysis of tool vibration and surface roughness during turning process of tempered steel samples using Taguchi method

2021 ◽  
pp. 095440892110019
Author(s):  
Menderes Kam ◽  
Mustafa Demirtaş
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Turning Process ◽  
Machining Time ◽  
Tool Vibration ◽  
Control Factors ◽  
Tempered Steel

This study analyzed the tool vibration (Vib) and surface roughness (Ra) during turning of AISI 4340 (34CrNiMo6) tempered steel samples using Taguchi Method. In this context, Taguchi design L18 (21 × 32) was used to analyze the experimental results. The vibration amplitude values from cutting tools were recorded for different machining parameters, control factors; two different sample hardness (46 and 53 HRc), three different cutting speeds (180, 220, 260 m.min−1), and feed rates (0.08, 0.14, 0.20 mm.rev−1) were selected. The machining parameters giving optimum Vib and Ra values were determined. Regression analysis is applied to predict values of Vib and Ra. Analysis of variance was used to determine the effects of machining parameters on the Vib and Ra values. The most important machining parameters were found to be the feed rate, sample hardness, and cutting speed for Vib and Ra, respectively. The lowest Vib and Ra values were obtained in 46 HRc sample as 0.0022 gRMS and 0.255 µm, respectively. The surface quality can be improved by reducing the sources of vibration by using appropriate machining parameters. As a result, there is a significant relationship between Ra and Vib. The lower Ra values were found during turning process of tempered steel samples according to the literature studies. It is suggested that the process can be preferred as an alternative process to grinding process due to lower cost and machining time. In application of the turning of experiment samples by ceramic cutting tool, a substantial technological and economical benefit has been observed.

Low Cost Vibration Measurement and Optimization during Turning Process

2018 ◽  
Vol 1148 ◽  
pp. 103-108 ◽  
Author(s):  
N.V.S. Shankar ◽  
A. Gopi Chand ◽  
K. Hanumantha Rao ◽  
K. Prem Sai
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Low Cost ◽  
Machining Process ◽  
Vibration Measurement ◽  
Depth Of Cut ◽  
Turning Process ◽  
Taguchi Analysis ◽  
Series Of Experiments

During machining any material, vibrations play a major role in deciding the life of the cutting tool as well as machine tool. The magnitude acceleration of vibrations is directly proportional to the cutting forces. In other words, if we are able to measure the acceleration experienced by the tool during machining, we can get a sense of force. There are many commercially available, pre-calibrated accelerometer sensors available off the shelf. In the current work, an attempt has been made to measure vibrations using ADXL335 accelerometer. This accelerometer is interfaced to computer using Arduino. The measured values are then used to optimize the machining process. Experiments are performed on Brass. During machining, it is better to have lower acceleration values. Thus, the first objective of the work is to minimize the vibrations. Surface roughness is another major factor which criterion “lower is the better” applies. In order to optimize the values, a series of experiments are conducted with three factors, namely, tool type (2 levels), Depth of cut (3 levels) and Feed are considered (3 levels). Mixed level optimization is performed using Taguchi analysis with L18 orthogonal array. Detailed discussion of the parameters shall be given in the article.

scholarly journals Optimization of cutting tool geometry and machining parameters in turning process

2020 ◽  
Author(s):  
S. Saravanamurugan ◽  
B. Shyam Sundar ◽  
R. Sibi Pranav ◽  
A. Shanmugasundaram
Keyword(s):  
Cutting Tool ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Turning Process

Effects of Machining Parameters on Surface Roughness when Ultra-High Precision Diamond Turning RSA443 Optical Aluminum

2019 ◽  
Vol 287 ◽  
pp. 30-34
Author(s):  
Zwelinzima Mkoko ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Silicon Content ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Turning Process ◽  
Optical Components ◽  
Box Behnken Design ◽  
Factors Influencing

In the globally competitive environment, surface roughness and finer tolerances are becoming stringent and certainly most critical for optical components. The aim of this study is to determine the effects of diamond turning process parameters on surface finish when diamond turning RSA 443 alloy having high silicon content. This alloy is a new grade of aluminum that has a potential to be used for production of various optical components. The experiments were conducted based on the Box-Behnken design with three diamond-turning parameters varied at three levels. A mathematical regression model was developed for predicting surface roughness. Further, the analysis of variance was used to analyze the influence of cutting parameters and their interaction in machining. The developed prediction model reveals that cutting speed and feed rate are the most dominant diamond turning factors influencing surface roughness.

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.

scholarly journals Research and Optimization of Surface Roughness in Milling of SLM Semi-Finished Parts Manufactured by Using the Different Laser Scanning Speed

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 9 ◽  
Author(s):  
Andrzej Matras
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Laser Scanning ◽  
Cutting Tool ◽  
Scanning Speed ◽  
Milling Process ◽  
Face Milling ◽  
Machining Parameters ◽  
The Face ◽  
Laser Scanning Speed

The paper studies the potential to improve the surface roughness in parts manufactured in the Selective Laser Melting (SLM) process by using additional milling. The studied process was machining of samples made of the AlSi10Mg alloy powder. The simultaneous impacts of the laser scanning speed of the SLM process and the machining parameters of the milling process (such as the feed rate and milling width) on the surface roughness were analyzed. A mathematical model was created as a basis for optimizing the parameters of the studied processes and for selecting the sets of optimum solutions. As a result of the research, surface with low roughness (Ra = 0.14 μm, Rz = 1.1 μm) was obtained after the face milling. The performed milling allowed to reduce more than 20-fold the roughness of the SLM sample surfaces. The feed rate and the cutting width increase resulted in the surface roughness deterioration. Some milled surfaces were damaged by the chip adjoining to the rake face of the cutting tool back tooth.

scholarly journals Analysis of Surface Roughness and Flank Wear Using the Taguchi Method in Milling of NiTi Shape Memory Alloy with Uncoated Tools

Coatings ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1259
Author(s):  
Emre Altas ◽  
Hasan Gokkaya ◽  
Meltem Altin Karatas ◽  
Dervis Ozkan
Keyword(s):  
Surface Roughness ◽  
Shape Memory Alloy ◽  
Shape Memory ◽  
Flank Wear ◽  
Cutting Tools ◽  
Dominant Factor ◽  
Niti Shape Memory Alloy ◽  
Machining Parameters ◽  
Nose Radius ◽  
Dry Cutting

The aim of this study was to optimize machining parameters to obtain the smallest average surface roughness (Ra) and flank wear (Vb) values as a result of the surface milling of a nickel-titanium (NiTi) shape memory alloy (SMA) with uncoated cutting tools with different nose radius (rε) under dry cutting conditions. Tungsten carbide cutting tools with different rε (0.4 mm and 0.8 mm) were used in milling operations. The milling process was performed as lateral/surface cutting at three different cutting speeds (Vc) (20, 35 and 50 m/min), feed rates (fz) (0.03, 0.07 and 0.14 mm/tooth) and a constant axial cutting depth (0.7 mm). The effects of machining parameters in milling experiments were investigated based on the Taguchi L18 (21 × 32) orthogonal sequence, and the data obtained were analyzed using the Minitab 17 software. To determine the effects of processing parameters on Ra and Vb, analysis of variance (ANOVA) was used. The analysis results reveal that the dominant factor affecting the Ra is the cutting tool rε, while the main factor affecting Vb is the fz. Since the predicted values and measured values are very close to each other, it can be said that optimization is correct according to the validation test results.

Cutting Performance of Al2O3/TiC/TiN Nanocomposite Tools

2010 ◽  
Vol 443 ◽  
pp. 318-323 ◽  
Author(s):  
Han Lian Liu ◽  
Chuan Zhen Huang ◽  
Bin Zou
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Tool Material ◽  
High Hardness ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Machining Parameters ◽  
Dry Cutting ◽  
Ceramic Cutting Tool ◽  
Multi Phase

A multi-scale and multi-phase nanocomposite ceramic cutting tool material Al2O3/TiC/TiN(LTN) with high comprehensive mechanical properties has been successfully fabricated by means of adding micro-scale TiC and nano-scale TiN particles. The cutting performance and wear mechanisms of this advanced ceramic cutting tool were researched by turning two kinds of hardened steel 40Cr and T10A respectively. Compared with the commercial ceramic tool LT55, LTN showed a superior wear resistance with certain machining parameters. The machining tests indicated that the new materials tool is suitable for continuously dry cutting of hardened steel with high hardness at high speed.

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