Modeling and Parameter Optimization for Surface Roughness and Residual Stress in Dry Turning Process

The influence of some turning variables and tool overhang on surface roughness parameters and residual stress induced due to machining 6061-T6 aluminum alloy is investigated in this paper. Four input parameters (cutting speed, feed rate, depth of cut and tool overhang) are considered. Tests are carried out by precision turning operation on a lathe. Design of experiment techniques, i.e. response surface methodology (RSM) and Taguchi's technique have been used to accomplish the objective of the experimental study. Surface roughness parameters are measured using a portable surface roughness device while residual stresses are measured employing deflection-etching technique using electrochemical analysis. The results obtained reveal that feed and rotational speed play significant role in determining the average surface roughness. Furthermore, the depth of cut and tool overhang are less significant parameters, whereas tool overhang interacts with feed rate. The best result of surface roughness was obtained using low or medium values of overhang with low speed and /or feed rate. Minimum maximum tensile residual stress can be obtained with a combination of tool overhang of 37 mm with very low depth of cut, low rotational speed and feed rate of 0.188 mm/rev.

Download Full-text

Evaluation of Process Parameters in Machining of AA6063 Alloy

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1148.109 ◽

2018 ◽

Vol 1148 ◽

pp. 109-114

Author(s):

M. Balaji ◽

C.H. Nagaraju ◽

V.U.S. Vara Prasad ◽

R. Kalyani ◽

B. Avinash

Keyword(s):

Surface Roughness ◽

Regression Analysis ◽

Process Parameters ◽

Single Channel ◽

Cutting Speed ◽

Cutting Parameters ◽

Depth Of Cut ◽

Roughness Parameters ◽

Surface Roughness Parameters ◽

Aa6063 Alloy

The main aim of this work is to analyse the significance of cutting parameters on surface roughness and spindle vibrations while machining the AA6063 alloy. The turning experiments were carried out on a CNC lathe with a constant spindle speed of 1000rpm using carbide tool inserts coated with Tic. The cutting speed, feed rate and depth of cut are chosen as process parameters whose values are varied in between 73.51m/min to 94.24m/min, 0.02 to 0.04 mm/rev and 0.25 to 0.45 mm respectively. For each experiment, the surface roughness parameters and the amplitude plots have been noted for analysis. The output data include surface roughness parameters (Ra,Rq,Rz) measured using Talysurf and vibration parameter as vibration amplitude (mm/sec) at the front end of the spindle in transverse direction using single channel spectrum analyzer (FFT).With the collected data Regression analysis is also performed for finding the optimum parameters. The results show that significant variation of surface irregularities and vibration amplitudes were observed with cutting speed and feed. The optimum cutting speed and feed from the regression analysis were 77.0697m/min and 0.0253mm/rev. for the minimum output parameters. No significant effect of depth of cut on output parameters is identified.

Download Full-text

EVALUATION OF SURFACE ROUGHNESS PRODUCED BY NANOCUTTING COPPER STRUCTURE USING A LEAST SQUARE MEAN METHOD

Surface Review and Letters ◽

10.1142/s0218625x19500811 ◽

2019 ◽

Vol 27 (01) ◽

pp. 1950081 ◽

Cited By ~ 1

Author(s):

CHUNHUI JI ◽

SHUANGQIU SUN ◽

BIN LIN ◽

TIANYI SUI

Keyword(s):

Surface Roughness ◽

Cutting Speed ◽

Least Square ◽

Depth Of Cut ◽

Real Surface ◽

Roughness Parameters ◽

Machined Surface ◽

Surface Roughness Parameters ◽

3D Surface ◽

3D Surface Roughness

This work performed molecular dynamic simulations to study the 2D profile and 3D surface topography in the nanometric cutting process. The least square mean method was used to model the evaluation criteria for the surface roughness at the nanometric scale. The result showed that the cutting speed was the most important factor influencing the spacing between the peaks, the sharpness of the peaks, and the randomness of the profile. The plastic deformation degree of the machined surface at the nanometric scale was significantly influenced by the cutting speed and depth of cut. The 2D and 3D surface roughness parameters exhibited a similar variation tendency, and the parameters Ra and Rq tended to increase gradually with an increase in the cutting speed and a decrease in the depth of cut. Finally, it is concluded that at the nanometric scale, the 3D surface roughness parameters could more accurately reflect the real surface characteristics than the 2D parameters.

Download Full-text

Surface Roughness and Residual Stresses of High Speed Turning 300 M Ultrahigh Strength Steel

Advances in Mechanical Engineering ◽

10.1155/2014/859207 ◽

2014 ◽

Vol 6 ◽

pp. 859207 ◽

Cited By ~ 2

Author(s):

Zhang Huiping ◽

Zhang Hongxia ◽

Lai Yinan

Keyword(s):

Residual Stress ◽

Surface Roughness ◽

Prediction Model ◽

Feed Rate ◽

High Speed ◽

Stress Test ◽

Orthogonal Cutting ◽

Cutting Speed ◽

Depth Of Cut ◽

Factors Affecting

Firstly, a single factor test of the surface roughness about tuning 300 M steel is done. According to the test results, it is direct to find the sequence of various factors affecting the surface roughness. Secondly, the orthogonal cutting experiment is carried out from which the primary and secondary influence factors affecting surface roughness are obtained: feed rate and corner radius are the main factors affecting surface roughness. The more the feed rate, the greater the surface roughness. In a certain cutting speed rang, the surface roughness is smaller. The influence of depth of cut to the surface roughness is small. Thirdly, according to the results of the orthogonal experiment, the prediction model of surface roughness is established by using regressing analysis method. Using MatLab software, the prediction mode is optimized and the significance test of the optimized model is done. It showed that the prediction model matched the experiment results. Finally, the surface residual stress test of turning 300 M steel is done and the residual stress of the surface and along the depth direction is measured.

Download Full-text

ESTIMATING THE EFFECT OF MACHINING PARAMETERS ON SURFACE ROUGHNESS DURING MACHINING OF HARDENED EN24 STEEL USING COATED CARBIDE INSERTS

International Journal of Mechanical and Industrial Engineering ◽

10.47893/ijmie.2014.1197 ◽

2014 ◽

pp. 123-128

Author(s):

Sudhansu Ranjan Das ◽

Amaresh Kumar ◽

Debabrata Dhupal ◽

Kali Charan Rath

Keyword(s):

Surface Roughness ◽

Cutting Speed ◽

Depth Of Cut ◽

Machining Parameters ◽

Roughness Parameters ◽

Surface Roughness Parameters ◽

Hardened En24 ◽

Coated Carbide ◽

The Relationship ◽

Carbide Inserts

In the present study, an attempt has been made to evaluate the performance of multilayer coated carbide inserts during dry turning of hardened EN24 steel (47 HRC). The effect of machining parameters (depth of cut, feed and cutting speed) on surface roughness parameters (Ra and Rz) were investigated by applying ANOVA. The experiments were planned based on Taguchi’s L27 Orthogonal array design. Results showed that surface roughness parameters (Ra and Rz) are mainly influenced by feed and cutting speed, whereas depth of cut exhibits minimum influence on surface roughness (Rz) and neglegible influence in case of surface roughness (Ra). The experimental data were further anlyzed to predict the optimal range of surface roughness parameters (Ra and Rz). Finally, second order regression models were carried out to find out the relationship between the machining parameters and surface roughness parameters.

Download Full-text

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.447-448.51 ◽

2010 ◽

Vol 447-448 ◽

pp. 51-54

Author(s):

Mohd Fazuri Abdullah ◽

Muhammad Ilman Hakimi Chua Abdullah ◽

Abu Bakar Sulong ◽

Jaharah A. Ghani

Keyword(s):

Surface Roughness ◽

Stainless Steel ◽

Surface Finish ◽

Feed Rate ◽

Cutting Speed ◽

Chip Thickness ◽

Cutting Parameters ◽

Depth Of Cut ◽

Nose Radius ◽

Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Download Full-text

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

Advanced Engineering Forum ◽

10.4028/www.scientific.net/aef.36.28 ◽

2020 ◽

Vol 36 ◽

pp. 28-46

Author(s):

Youssef Touggui ◽

Salim Belhadi ◽

Salah Eddine Mechraoui ◽

Mohamed Athmane Yallese ◽

Mustapha Temmar

Keyword(s):

Surface Roughness ◽

Cutting Force ◽

Feed Rate ◽

Cutting Speed ◽

Cutting Parameters ◽

Depth Of Cut ◽

Aisi 316L ◽

Cutting Power ◽

Dry Turning ◽

Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

Download Full-text

Characterisation, Performance and Optimisation of Nanocellulose Metalworking Fluid (MWF) for Green Machining Process

International Journal of Automotive and Mechanical Engineering ◽

10.15282/ijame.18.4.2021.04.0707 ◽

2021 ◽

Vol 18 (4) ◽

pp. 9188-9207

Author(s):

Mahendran Samykano ◽

J. Kananathan ◽

K. Kadirgama ◽

A. K. Amirruddin ◽

D. Ramasamy ◽

...

Keyword(s):

Thermal Conductivity ◽

Surface Roughness ◽

Tool Wear ◽

Feed Rate ◽

Cutting Speed ◽

Machining Process ◽

Alumina Nanoparticles ◽

Working Fluid ◽

Depth Of Cut ◽

Nanoparticle Concentration

The present research attempts to develop a hybrid coolant by mixing alumina nanoparticles with cellulose nanocrystal (CNC) into ethylene glycol-water (60:40) and investigate the viability of formulated hybrid nanocoolant (CNC-Al2O3-EG-Water) towards enhancing the machining behavior. The two-step method has been adapted to develop the hybrid nanocoolant at various volume concentrations (0.1, 0.5, and 0.9%). Results indicated a significant enhancement in thermal properties and tribological behaviour of the developed hybrid coolant. The thermal conductivity improved by 20-25% compared to the metal working fluid (MWF) with thermal conductivity of 0.55 W/m℃. Besides, a reduction in wear and friction coefficient was observed with the escalation in the nanoparticle concentration. The machining performance of the developed hybrid coolant was evaluated using Minimum Quantity Lubrication (MQL) in the turning of mild steel. A regression model was developed to assess the deviations in the tool flank wear and surface roughness in terms of feed, cutting speed, depth of the cut, and nanoparticle concentration using Response Surface Methodology (RSM). The mathematical modeling shows that cutting speed has the most significant impact on surface roughness and tool wear, followed by feed rate. The depth of cut does not affect surface roughness or tool wear. Surface roughness achieved 24% reduction, 39% enhancement in tool length of cut, and 33.33% improvement in tool life span. From this, the surface roughness was primarily affected by spindle cutting speed, feed rate, and then cutting depth while utilising either conventional water or composite nanofluid as a coolant. The developed hybrid coolant manifestly improved the machining behaviour.

Download Full-text

Investigations on Surface Roughness and Tool Wear Characteristics in Micro-Turning of Ti-6Al-4V Alloy

Materials ◽

10.3390/ma13132998 ◽

2020 ◽

Vol 13 (13) ◽

pp. 2998 ◽

Cited By ~ 6

Author(s):

Kubilay Aslantas ◽

Mohd Danish ◽

Ahmet Hasçelik ◽

Mozammel Mia ◽

Munish Gupta ◽

...

Keyword(s):

Surface Roughness ◽

Feed Rate ◽

Removal Rate ◽

Cutting Speed ◽

Small Diameter ◽

Cutting Parameters ◽

Ti6al4v Alloy ◽

Depth Of Cut ◽

Turning Process ◽

Micro Turning

Micro-turning is a micro-mechanical cutting method used to produce small diameter cylindrical parts. Since the diameter of the part is usually small, it may be a little difficult to improve the surface quality by a second operation, such as grinding. Therefore, it is important to obtain the good surface finish in micro turning process using the ideal cutting parameters. Here, the multi-objective optimization of micro-turning process parameters such as cutting speed, feed rate and depth of cut were performed by response surface method (RSM). Two important machining indices, such as surface roughness and material removal rate, were simultaneously optimized in the micro-turning of a Ti6Al4V alloy. Further, the scanning electron microscope (SEM) analysis was done on the cutting tools. The overall results depict that the feed rate is the prominent factor that significantly affects the responses in micro-turning operation. Moreover, the SEM results confirmed that abrasion and crater wear mechanism were observed during the micro-turning of a Ti6Al4V alloy.

Download Full-text

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

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405415583776 ◽

2015 ◽

Vol 231 (6) ◽

pp. 913-923 ◽

Cited By ~ 15

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.

Download Full-text