Utility of Taguchi Grey Relation Analysis for Influencing the System Input Parameters and Impacts of Tool Geometry and Wear Response of the Cutting Tool on Machinability and Environmental Impact of Machining for Automobile Industries

2021 ◽  
Vol 13 (2) ◽  
Author(s):  
Durai Kumaran ◽  
S.P. Sundar Singh Sivam ◽  
Harshavardhana Natarajan ◽  
G. Balakumaran ◽  
R. Naveen
Keyword(s):  
Operating Time ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Waste Streams ◽  
Nose Radius ◽  
Cooperative Effects ◽  
System Input

Amid the delivering of an item, any material or abundance vitality created moreover to a definitive item will be named as waste. The waste produced in light of machining could be a noteworthy ecological worry for creators. The shape and condition of waste streams created and their transportation components contrast with the strategy utilized and also shift among the technique. The effect in view of each waste stream differs as well. This examination reports a machining strategy includes the procedure of material to give a completed or a semicompleted item. This is frequently done to abuse tools, frills, machines and distinctive data sources that are appropriate to the strategy. The procedures for this work include machining of material abuse devices to give parts and items. The yield of the technique incorporates the item and thusly the waste streams. The waste streams convey with the material inside the kind of chips, energy usage, worn cutting tools and operating time. Grey relational analysis and ANOVA was acclimated with the chief essential cutting speed, feed rate, depth of cut and tool nose radius conditions that influence the minimum response. The cooperative effects of the informational factors on the normal reactions are researched. The normal and estimated esteems are genuinely close. The given model may be acclimated to pick the measure of machining process parameters.

scholarly journals Machining force comparison for surface defect hard turning and conventional hard turning of AISI 52100 steel

2021 ◽  
Vol 13 (3) ◽  
pp. 205-214
Author(s):  
P. U MAMAHESWARRAO ◽  
D. RANGARAJU ◽  
K. N. S. SUMAN ◽  
B. RAVISANKAR
Keyword(s):  
Hard Turning ◽  
Surface Defect ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 52100 ◽  
Machining Force ◽  
Aisi 52100 Steel ◽  
The Impact

In this article, a recently developed method called surface defect machining (SDM) for hard turning has been adopted and termed surface defect hard turning (SDHT). The main purpose of the present study was to explore the impact of cutting parameters like cutting speed, feed, depth of cut, and tool geometry parameters such as nose radius and negative rake angle of the machining force during surface defect hard turning (SDHT) of AISI 52100 steel in dry condition with Polycrystalline cubic boron nitride (PCBN) tool; and results were compared with conventional hard turning (CHT). Experimentation is devised and executed as per Central Composite Design (CCD) of Response Surface Methodology (RSM). Results reported that an average machining force was decreased by 22% for surface defect hard turning (SDHT) compared to conventional hard turning (CHT).

scholarly journals Mechanistic modeling of cutting forces in high-speed microturning of titanium alloy with consideration of nose radius

2021 ◽  
Author(s):  
Kubilay Aslantas ◽  
Şükrü Ülker ◽  
Ömer Şahan ◽  
Danil Yu Pimenov ◽  
Khaled Giasin
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Mechanistic Model ◽  
Cutting Speed ◽  
Mechanistic Modeling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Multilinear Regression Analysis ◽  
Edge Radius

AbstractMicroturning is a micromechanical machining process used to produce microcylindrical or axially symmetrical parts. Microcylindrical parts are mainly used in microfluidic systems, intravenous micromotors, microsurgical applications, optical lens applications, and microinjection systems. The workpiece diameter is very small in microturning and therefore is greatly affected by the cutting forces. For this reason, it is important to predict the cutting forces when machining miniature parts. In this study, an analytical mechanistic model of microturning is used to predict the cutting forces considering the tool nose radius. In the semi-empirically developed mechanistic model, the tool radius was considered. A series of semi-orthogonal microturning cutting tests were carried out to determine the cutting and edge force coefficients. The mechanistic model was generalized depending on the cutting speed and depth of cut by performing multilinear regression analysis. In the study, the depth of cut (ap = 30–90 µm) and feed values (f = 0.5–20 µm/rev) were selected considering the nose radius and edge radius of the cutting tool. The experiments were carried out under high-cutting speeds (Vc = 150–500 m/min) and microcutting conditions. Ti6Al4V alloy was used as the workpiece material and the tests were carried out under dry cutting conditions. Validation tests for different cutting parameters were carried out to validate the accuracy of the developed mechanistic model. The results showed that the difference between the mechanistic model and the experimental data was a minimum of 3% and a maximum of 24%. The maximum difference between the experimental and the model usually occurs in forces in the tangential direction. It has been observed that the developed model gives accurate results even at a depth of cut smaller than the nose radius and at feed values smaller than the edge radius.

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).

Minimisation of specific cutting energy and back force in turning of AISI 1060 steel

2017 ◽  
Vol 232 (11) ◽  
pp. 2019-2029 ◽  
Author(s):  
Sourabh Paul ◽  
PP Bandyopadhyay ◽  
S Paul
Keyword(s):  
Cutting Tools ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Nose Radius ◽  
Cutting Energy ◽  
High Feed ◽  
Individual Criterion ◽  
Carbide Inserts

A lot of research has been undertaken in the area of conventional machining to study the effect of process parameters, tool geometry, machining environment and so on on machinability. But only recently, the research community has started analysing the carbon footprint of manufacturing processes. But very few articles could be located that attempted simultaneous minimisation of specific cutting energy and back force over a wide domain of process and tool-geometric parameters. This article has experimentally studied the effect of variation in depth of cut, feed, nose radius and tool geometry on simultaneous minimisation of specific cutting energy and back force while turning AISI 1060 steel with uncoated carbide inserts under dry machining environment. Minimisation of specific cutting energy and back force as individual criterion leads to conflicting choice of machining parameters. A combined criterion based on specific cutting energy and back force has been defined and for the minimisation of the same, cutting tools with positive rake need to be used, with high feed and moderate depth of cut.

scholarly journals Optimal Machining Parameters for Achieving the Desired Surface Roughness in Turning of Steel

2012 ◽  
Vol 9 (1) ◽  
pp. 37 ◽  
Author(s):  
LB Abhang ◽  
M Hameedullah
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Engineering Sciences

 Due to the widespread use of highly automated machine tools in the metal cutting industry, manufacturing requires highly reliable models and methods for the prediction of output performance in the machining process. The prediction of optimal manufacturing conditions for good surface finish and dimensional accuracy plays a very important role in process planning. In the steel turning process the tool geometry and cutting conditions determine the time and cost of production which ultimately affect the quality of the final product. In the present work, experimental investigations have been conducted to determine the effect of the tool geometry (effective tool nose radius) and metal cutting conditions (cutting speed, feed rate and depth of cut) on surface finish during the turning of EN-31 steel. First and second order mathematical models are developed in terms of machining parameters by using the response surface methodology on the basis of the experimental results. The surface roughness prediction model has been optimized to obtain the surface roughness values by using LINGO solver programs. LINGO is a mathematical modeling language which is used in linear and nonlinear optimization to formulate large problems concisely, solve them, and analyze the solution in engineering sciences, operation research etc. The LINGO solver program is global optimization software. It gives minimum values of surface roughness and their respective optimal conditions. 

Effect of Cutting Parameters on Surface Texture of Flame Sprayed Coatings

2013 ◽  
Vol 199 ◽  
pp. 396-401
Author(s):  
Robert Starosta
Keyword(s):  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Clearance Angle ◽  
Approach Angle ◽  
Cutting Inserts

Coatings were turned by two tools: a) ISO 2R 2525K10, geometry and cutting parameters recommended by Messner Eutectic Castolin Company (tool angle β = 90o, approach angle κr = 45o, nose radius rε =0,8 mm, clearance angle α = 6o, rake angle γ = -5o) b) bit tool with CBN WNGA080408S01030A insert mounted in DWLNRL-2525M08 holder (cutting inserts β = 80o, approach angle κr = 95o, nose radius 0,8 mm, clearance angle α = 6o, rake angle γ = -6o). The influence of cutting speed, feed rate, depth of turning on the coating surface roughness was estimated. The following cutting parameters: cutting speed Vc = 45 214 m/min, feed rate f = 0,04 0,196 mm/rev, depth of cut ap = 0,05 0,3 mm. The lowest value of the roughness Ra = 0,5μm of the coatings were obtained by using cutting tools and parameters and bit tool: Vc = 214 m/min, f = 0,06 mm/rev, ap = 0,3 mm.

The Study of Precision Hard Turning of the Hardened Mold Steel

2007 ◽  
Vol 364-366 ◽  
pp. 640-643 ◽  
Author(s):  
Wei Shin Lin
Keyword(s):  
Surface Roughness ◽  
Hard Turning ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Nose Radius ◽  
Grinding Processes ◽  
Energy Consuming ◽  
Turning Test

Hard turning has the advantage of rapidly, elasticity and low energy consuming. It has been a trend to replace the complex grinding processes, especially for small batch machining.The surface roughness value of steel after being grinded will ranged in 0.1 to 1.6 μm Ra. This paper points to the precision hard turning of the hardened mold steel, seeking the cutting conditions that can be received in the surface roughness value below 0.1μm Ra, in order to replace the grinding processes. The precision dry turning test were conducted with ceramic cutting tools. The nose radius of the cutting tool was 1.2 mm and the depth of cut was fixed at 0.05 mm. Through a series of turning test, it can be found that, when cutting speed was at 80 to 200 m / min, and feed rate at 0.005 to 0.009 mm / rev, the surface roughness value would be all below 0.1μm Ra. It was superior to grinding process. So we can say that, it is possible to replace the grinding process by hard turning when machining the hardened mold steel.

Influence of Tool Nose Radius and Cutting Performance during Face Milling of Magnesium Alloy for Output Responses by Taguchi based Grey Relation Analysis

2021 ◽  
Vol 13 (2) ◽  
Author(s):  
Durai Kumaran ◽  
S.P. Sundar Singh Sivam ◽  
Harshavardhana Natarajan ◽  
P.R. Shobana Swarna Ratna
Keyword(s):  
Removal Rate ◽  
Cutting Speed ◽  
Face Milling ◽  
Machining Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
New Approach ◽  
Grey Relational Grade ◽  
Grey Relational

In order to take advantage of the machining characteristics of magnesium, it is useful to consider recommended tool design and angles. The geometry of the tool can have a large influence on the machining process. Tool geometry can be used to aid with chip flow and clearance, reduce excessive heat generation, reduce tool build up, enable greater feed rates to be employed and improved tool life. This paper presents a new approach for the optimization of machining parameters on face milling of ZE41 with multiple responses based on orthogonal array with grey relational analysis. Machining tests are carried out by inserting 12 mm diameter of insert having 1 flute under dry condition. In this study, machining parameters namely cutting speed, feed and depth of cut and tool node radius are optimized with the considerations of multi responses such as surface roughness, material removal rate, tool wear and thrust force. A grey relational grade is obtained from the grey analysis. Based on the grey relational grade, optimum levels of parameters have been identified and significant contribution of parameters is determined by ANOVA. Confirmation test is conducted to validate the test result. Experimental results have shown that the responses in Machining process can be improved effectively through the new approach.

scholarly journals PENGARUH VARIASI SUDUT UJUNG MATA POTONG KARBIDA TERHADAP KEKASARAN DAN TOPOGRAFI PERMUKAAN LOGAM Al 6061 PADA PROSES PEMBUBUTAN

POROS ◽  
2018 ◽  
Vol 15 (1) ◽  
pp. 18
Author(s):  
Sobron Lubis ◽  
Rosehan Rosehan ◽  
Rico Wiguna
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Surface Condition ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Percentage Decrease ◽  
Tool Nose Radius

Abstract: In the process of metal cutting, cutting tools is an important factor to consider. Selection of cutting parameters and cutting tools geometry contributes to the surface condition of the resulting workpiece, especially surface roughness. The nose radius of cutting tools is a piece that rubs against the workpiece that will form a scratch to produce a flake. Various types of cutting tools angles today are developed and certainly give effect to changes in surface roughness of the workpiece and topography. To know the condition of surface workpiece produced, then conducted research influence variation tool nose radius cutting tools to roughness and topography surface workpiece. This research was conducted using CNC lathe. Three variations of end of carbide insert tip used i.e. 0.4, 0.8, and 1.2 mm are installed. Right on tool holder cutting tools. The cutting speed used is 500 m / min, depth of cut 0.2 mm, and feeding of 0.3 mm / put. Material workpiece aluminum alloy type 6061 turning without using coolant. The workpiece of the lathe result is measurement of surface roughness by using Mitutoyo surface test, and observation of workpiece surface condition done by Jenco digital microscope model BC 4-311. The result of the analysis shows that the surface roughness value is inversely proportional to the increase of nose radius cutting tools tool. The larger the nose radius cutting tools, the smaller the surface roughness. The lowest roughness value is 1.046 μm with cutting speed of 500 m / min and 1.2 mm tool nose radius cutting tools. The percentage decrease in surface roughness with the difference of nose radius cutting tools tool is 12.24%. 

Deformation Replication

1970 ◽  
Vol 28 ◽  
pp. 280-281
Author(s):  
J. Temple Black
Keyword(s):  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Rake Face ◽  
Orthogonal Machining ◽  
Aluminum Chips ◽  
Before And After ◽  
Materials Used ◽  
Glass Knife ◽  
Very High

Tool materials used in ultramicrotomy are glass, developed by Latta and Hartmann (1) and diamond, introduced by Fernandez-Moran (2). While diamonds produce more good sections per knife edge than glass, they are expensive; require careful mounting and handling; and are time consuming to clean before and after usage, purchase from vendors (3-6 months waiting time), and regrind. Glass offers an easily accessible, inexpensive material ($0.04 per knife) with very high compressive strength (3) that can be employed in microtomy of metals (4) as well as biological materials. When the orthogonal machining process is being studied, glass offers additional advantages. Sections of metal or plastic can be dried down on the rake face, coated with Au-Pd, and examined directly in the SEM with no additional handling (5). Figure 1 shows aluminum chips microtomed with a 75° glass knife at a cutting speed of 1 mm/sec with a depth of cut of 1000 Å lying on the rake face of the knife.

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