scholarly journals Evaluation of the Performance of Cryogenically Treated Carbide İnserts in the Turning of AISI 1040 Steel

2021 ◽  
Vol 10 (2) ◽  
pp. 25-30
Author(s):  
Adnan Calik ◽  
Keyword(s):  
Surface Roughness ◽  
Wear Resistance ◽  
Feed Rate ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
The Other ◽  
Coated Layer ◽  
Cryogenic Processing ◽  
Carbide Inserts ◽  
Very High

-In this study, the effects of cryogenic treatment on tool wear and surface roughness of tungsten carbide inserts coated with TiAlN were investigated as a function of cutting speed and feed rate. It is observed that the surface roughness increases with increased cutting speed, feed rate and also applied cryogenic processing. In other words, the effect of feed rate and cutting speed is very high on the surface roughness. On the other hand, the results showed that the cryogenic treatment is a non-effective process to enhance the wear resistance and tool life of inserts due to brittle region between coated layer and surface

Taguchi optimization of surface roughness in the turning of Hastelloy C22 super alloy using cryogenically treated ceramic inserts

2020 ◽  
Vol 234 (19) ◽  
pp. 3826-3836
Author(s):  
Sıtkı Akincioğlu ◽  
Hasan Gökkaya ◽  
Gülşah Akincioğlu ◽  
Meltem A Karataş
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cryogenic Treatment ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Deep Cryogenic Treatment ◽  
Taguchi Optimization ◽  
Factors Affecting ◽  
Treatment Type ◽  
Super Alloy

Cryogenic treatment has been used in recent years to improve the performance of cutting tools. This study evaluated the machinability of a nickel–molybdenum-based super alloy using cryogenically treated (–80 ℃ and –145 ℃) ceramic inserts under dry turning conditions. Three cutting speeds (350, 400, and 450 m/min), three feed rates (0.1, 0.2, and 0.3 mm/rev), and a 1-mm fixed cutting depth were used in the turning tests. Experiments were conducted using the Taguchi orthogonal array L27 design. The factors affecting the surface roughness (Ra) were determined via analysis of variance. The effect of cryogenic treatment type (shallow and deep), cutting speed, and feed rate on surface roughness was investigated. Results of the analysis determined that the feed rate was the major parameter that affected surface roughness and that the deep cryogenic treatment was more effective. The regression analysis confirmed that the experimental results and the predicted values were within the 95% confidence interval. The most effective parameter affecting the surface roughness was feed rate at a contribution of 57.9%. The contribution of the cutting tool type to the surface roughness was 28.5%. The results obtained showed that the surface roughness can be optimized for turning the Hastelloy c22 super alloy with the Taguchi method.

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

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.

Experimental Determination of Optimal Speeds for Alloy Steels in Plane Turning

2008 ◽  
Author(s):  
T. Srikanth ◽  
V. Kamala
Keyword(s):  
Surface Roughness ◽  
Force Measurement ◽  
Cutting Speed ◽  
Vital Role ◽  
The Other ◽  
Depth Of Cut ◽  
Work Piece ◽  
Material Interface ◽  
Alloy Steels

In machining, speeds play vital role. The operator should know exactly the speed at which machining should be performed to get the required surface finish. In this paper, an attempt is made to determine the optimal cutting speed for machining of alloy steels. Three work piece materials having different hardness are taken and machined using a round nose tool with a coated tip. The tool dynamometer is attached to the tool post for force measurement. Turning operation on the work piece is performed on lathe at four different speeds, keeping the feed and depth of cut constant. Cutting forces acting on the tool, temperature at the tool and material interface are recorded. Power consumed being determined by a wattmeter and surface roughness values are measured. The same procedure is repeated for the other two work-pieces materials and optimal speeds for machining are determined for the three specimens. The results obtained are compared with the theoretical values and found to be very close.

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

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

scholarly journals Technics Research on Polycrystalline Cubic Boron Nitride Cutting Tools Dry Turning Ti-6AL-4V Alloy Based on Orthogonal Experimental Design

2018 ◽  
Vol 142 ◽  
pp. 03002
Author(s):  
Yunhai Jia ◽  
Lixin Zhu
Keyword(s):  
Surface Roughness ◽  
Experimental Design ◽  
Boron Nitride ◽  
Feed Rate ◽  
Flank Wear ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Orthogonal Experimental Design ◽  
Polycrystalline Cubic Boron Nitride

Ti-6Al-4V components are the most widely used titanium alloy products not only in the aerospace industry, but also for bio-medical applications. The machine-ability of titanium alloys is impaired by their high temperature chemical reactivity, low thermal conductivity and low modulus of elasticity. Polycrystalline cubic boron nitride represents a substitute tool material for turning titanium alloys due to its high hardness, wear resistance, thermal stability and hot red hardness. For determination of suitable cutting parameters in dry turning Ti-6AL-4V alloy by Polycrystalline cubic boron nitride cutting tools, the samples, 300mm in length and 100mm in diameter, were dry machined in a lathe. The turning suitable parameters, such as cutting speed, feed rate and cut depth were determined according to workpieces surface roughness and tools flank wear based on orthogonal experimental design. The experiment showed that the cutting speed in the range of 160~180 m/min, the feed rate is 0.15 mm/rev and the depth of cut is 0.20mm, ideal workpiece surface roughness and little cutting tools flank wear can be obtained.

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

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.

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

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2998 ◽  
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.

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.

Experimental Evaluation of Surface Roughness in Orthogonal Micro-Milling Processes

2012 ◽  
Vol 217-219 ◽  
pp. 1912-1916
Author(s):  
Ji Hua Wu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Experimental Approach ◽  
Critical Role ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Micro Milling ◽  
Surface Model ◽  
Material Grain Size

Surface roughness plays a critical role in evaluating and measuring the surface quality of a machined product. Two workpiece materials have been investigated by experimental approach in order to gain a better understanding of their influence on the obtained surface roughness in the micro-milling processes. The experimental results show that: surface topography is completely different for different materials at the same cutting speed and feed rate; surface roughness increases with an increase of material grain size. Surface roughness decreases to a lowest value, and then increases with an increase of the feed rate. A new surface model to illustrate the influence of material and uncut chip thickness was developed. The model has been experimentally validated and shows more promising results than Weule’s model.

Feasibility Study of the Effectiveness of Cryogenically Treated Ceramic Inserts for Pocket Milling Maneuvers

2009 ◽  
Author(s):  
Justin L. Milner ◽  
Jeffrey A. Beers ◽  
John T. Roth
Keyword(s):  
Wear Resistance ◽  
Tool Wear ◽  
Feasibility Study ◽  
High Speed ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Initial Study ◽  
Machining Processes ◽  
Cutting Speeds

Machining is a popular and versatile manufacturing process that is widely used in today’s industry when producing metallic parts; however, limited tool life can make this an expensive and time consuming fabrication technique. Consequently, methods that decrease the rate of tool wear and, thus, increase tool longevity are a vital component when improving the efficiency of machining processes. To this end, cryogenically treating cutting tools (especially high-speed steel tooling) is becoming more commonplace since research has shown that the treated tooling exhibits significantly higher wear resistance. At this point, however, the effect of cryogenic treatments on ceramic tooling has not been established. Considering this, the research herein presents a feasibility study on the effectiveness of using cryogenic treatments to enhance the wear resistance of WG-300 whisker-reinforced ceramic cutting inserts. To begin, the effect of the cryogenic treatment on the insert’s hardness is examined. Subsequently, tool wear tests are conducted at various cutting speeds. Through this study, it is shown that cryogenically treating the ceramic inserts decreases the rate of tool wear at each of the cutting speeds that were tested. However, the degree of wear resistance introduced by cryogenically treating the inserts proved to be highly dependent on the cutting speed, with slower speeds exhibiting greater improvements. Thus, based on this initial study, the cryogenic treatment of ceramic tooling appears to produce beneficial results, potentially increasing the overall efficiency of machining processes.

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