scholarly journals Process Capability Assessment Using Vision System

2021 ◽  
Vol 13 (2) ◽  
pp. 96-102
Author(s):  
Shivanna Dodda Mallappa ◽  
◽  
Kiran Mysore Bhaskar ◽  
Venkatesh Gude Subbaraya ◽  
Kavitha Shimoga Divakar ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Vision System ◽  
Research Work ◽  
Stable Process ◽  
Process Capability ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Measuring Surface ◽  
Roughness Assessment

Surface roughness assessment would help in predicting a component’s functionality. This clearly shows the significance of measuring the surface roughness of machined components. Thus, each machined component, depending upon its intended function, requires a certain surface finish. To predict the surface roughness of a machined component, a detailed understanding of the machining parameters is essential. This is because, surface roughness generated on a component, depends upon machining parameters speed, feed, and depth of cut. A stable manufacturing process gives a consistent surface finish on all the manufactured components. Thus, only by having a stable process, consistent quality of manufactured products is possible. The capability of the machine is defined as the capability of the machine to carry out the set process efficiently and effectively to produce parts as per the specification limits. Machining parameters, tools, coolant flow rate, etc. An effort has been made in this research work, to show how by measuring surface roughness of machined components process capability can be assessed. Thus, the method is a novel technique of assessing the process capability of a given process. A capable process would help a manufacturing company in meeting customer expectations. The proposed method is of non-contact type, quick, and industry-friendly.

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 The Experimental Investigation of Surface Roughness After Dry Turning of Steel S235

2019 ◽  
Vol 26 (4) ◽  
pp. 179-184
Author(s):  
Justyna Molenda
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Scientific Work ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Workpiece Material ◽  
Important Indicator

AbstractNowadays lot of scientific work inspired by industry companies was done with the aim to avoid the use of cutting fluids in machining operations. The reasons were ecological and human health problems caused by the cutting fluid. The most logical solution, which can be taken to eliminate all of the problems associated with the use of cooling lubricant, is dry machining. In most cases, however, a machining operation without lubricant finds acceptance only when it is possible to guarantee that the part quality and machining times achieved in wet machining are equalled or surpassed. Surface finish has become an important indicator of quality and precision in manufacturing processes and it is considered as one of the most important parameter in industry. Today the quality of surface finish is a significant requirement for many workpieces. Thus, the choice of optimized cutting parameters is very important for controlling the required surface quality. In the present study, the influence of different machining parameters on surface roughness has been analysed. Experiments were conducted for turning, as it is the most frequently used machining process in machine industry. All these parameters have been studied in terms of depth of cut (ap), feed rate (f) and cutting speed (vc). As workpiece, material steel S235 has been selected. This work presents results of research done during turning realised on conventional lathe CDS 6250 BX-1000 with severe parameters. These demonstrate the necessity of further, more detailed research on turning process results.

scholarly journals Optimization of Turning Parameter of Composite Materials Using Response Surface Method in Minitab

2021 ◽  
Author(s):  
S. S Kulkarni ◽  
Sarika Sharma
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Research Work ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Rsm Optimization

This paper represents the optimization method utilized in machining process for figuring out the most advantageous manner design. Typically, the technique layout parameters in machining procedures are noticeably few turning parameters inclusive of reducing velocity, feed and depth. The optimization of speed, feed depth of cut is very tough because of several other elements associated with processing situations and form complexities like surface Roughness, material removal rate (MRR) that are based Parameters. On this task a new fabric glass fibre composite is introduced through which could lessen costing of manufacturing and time and additionally it will boom the technique of productiveness. Composite substances have strength, stiffness, light weight, which gives the large scope to engineering and technology. The proposed research work targets to analyze turning parameters of composite material. The machining parameters are very important in manufacturing industries. The present research work is optimized surface roughness of composite material specifically in turning procedure with the aid of changing parameter including intensity of reduce, slicing velocity and feed price and additionally expect the mechanical houses of composite material. The RSM optimization is important because it evaluates the effects of multiple factors and their interactions on one or more responsive variables. It is observed that the material removal rate increases and surface roughness decreases as per the increase of Spindle speed and feed rate.

Optimization of Cutting Parameters for Turning Operation of Titanium Alloy Ti-6Al-4V Material Workpiece Using the Taguchi Method

2013 ◽  
Vol 685 ◽  
pp. 57-62
Author(s):  
Seyyed Pedram Shahebrahimi ◽  
Abdolrahman Dadvand
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Taguchi Method ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Material Tool

One of the most important issues in turning operations is to choose suitable parameters in order to achieve a desired surface finish. The surface finish in machining operation depends on many parameters such as workpiece material, tool material, tool coating, machining parameters, etc. The purpose of this research is to focus on the analysis of optimum cutting parameters to get the lowest surface roughness in turning Titanium alloy Ti-6Al-4V with the insert with the standard code DNMG 110404 under dry cutting condition, by the Taguchi method. The turning parameters are evaluated as cutting speed of 14, 20 and 28 m/min, feed rate of 0.12, 0.14 and 0.16 mm/rev, depth of cut of 0.3, 0.6 and 1 mm, each at three levels. The Experiment was designed using the Taguchi method and 9 experiments were conducted by this process. The results are analyzed using analysis of variance method (ANOVA). The results of analysis show that the depth of cut has a significant role to play in producing lower surface roughness that is about 63.33% followed by feed rate about 30.25%, and cutting speed has less contribution on the surface roughness. Also it was realized that with the use of the confirmation test, the surface roughness improved by 227% from its initial state.

scholarly journals Surface Roughness Optimization Of Machining Parameters In Machining Of Composite Materials

2011 ◽  
pp. 26-32
Author(s):  
M. Ramesh ◽  
R.P. Elvin ◽  
K. Palanikumar ◽  
K.Hemachandra Reddy
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Production Costs ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Mechanical Parts ◽  
Taguchi’S Technique ◽  
Performance Surface ◽  
Carbide Insert

The term machinability refers to the ease with which a metal can be machined to an acceptance surface finish. The factors that typically improve a material’s performance often degrade its machinability. Therefore, to manufacture components economically, engineers are challenged to find ways to improve machinability without harming performance. Surface finish is an important parameter in manufacturing engineering. It is a characteristic that can influence the performance of mechanical parts and production costs. The investigation of influence of cutting conditions in turning of Duplex Stainless Steel 2205 is made in this project. The experimental design was formed based on Taguchi’s technique. An orthogonal array and analysis of variance (ANNOVA) are employed to investigate the turning conditions and machining was done using CVD triangular carbide insert. The objective was to establish correlation between cutting speed, feed rate and depth of cut and optimize the turning conditions based on surface roughness. These correlations are obtained by multiple regression analysis.

scholarly journals Effect of Coolant Temperature on Surface Finish during Turning of Titanium Alloy Ti6Al4V

2018 ◽  
Vol 3 (4) ◽  
pp. 237-244 ◽  
Author(s):  
Temitayo Samson Ogedengbe ◽  
Sulaimon Abdulkareem ◽  
Jacob Olayiwola Aweda
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cooling System ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Considerable Effect ◽  
Core Material ◽  
Coolant Temperature ◽  
Depth Of Cut ◽  
Machining Parameters

High temperature generated and stresses induced as a result of turning of Ti6Al4V results in poor surface finish. The aim of this study was to investigate the effect of coolant temperature on the surface roughness of Ti6Al4V which is a core material used as an implant. A cooling system was developed to reduce the temperature of the coolant (soluble oil) from room temperature to 2oC. Ti6Al4V was turned in dry and cooled (at temperatures 5, 7, 9 and 11 oC) conditions. The experiment was designed using central composite design of (Response surface methodology) Design Expert 11.0 to generate an array and optimize the machining parameters. The machining parameters used were cutting speed, feed rate, depth of cut and coolant temperature. Results analyses show that cutting speed and depth of cut had considerable effect on surface roughness of Ti6Al4V. Surface roughness reduced when coolant temperature was reduced. The results of this study shows that turning Ti6Al4V at a very low cutting temperature will ensure a better surface finish.

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 machining parameters and vibration on polymethylmethacrylate curved surface in single-point diamond turning

2020 ◽  
pp. 251659842094172
Author(s):  
Kuldeep A. Mahajan ◽  
Raju Pawade
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Feed Rate ◽  
Single Point ◽  
Optical Devices ◽  
Diamond Turning ◽  
Curved Surface ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Workpiece Material

Single-point diamond turning (SPDT) is an emerging process for achieving nanometric surface finish, required in various optical devices made from metals like aluminum, copper, and nonmetals like polymers. The optical devices are manufactured in different shapes and profiles, preferably flat and curved surfaces. During the manufacturing of optical devices, controllable and noncontrollable parameters affect the desired surface finish. In this article, controllable machining parameters such as the incremental distance of X slide, feed rate, spindle speed, and depth of cut are selected to study their effect on surface finish and vibration generation of the curved surface. The chosen workpiece material is polymethylmethacrylate (PMMA). Design of experiment (DoE) is used to find out the optimum parameters of surface finish and infeed vibration responses. According to the Taguchi and analysis of Variance (ANOVA) analysis, the feed rate is the most influencing parameter for surface roughness, and incremental distance is for infeed vibration. A confirmation test is carried out to verify the experimental responses with a mathematical regression model, and it shows a close difference within 2.7 percent. Further, minimum surface roughness is perceived as 12.4 nm, corresponding to an infeed vibration amplitude of 4.9 µm/s2, which is signified at a lower frequency.

scholarly journals Effect of Nose Radius on Surface Roughness of Diamond Turned Germanium Lenses

2021 ◽  
Author(s):  
Adeniyi Adeleke ◽  
Abou-El-Hossein Khaled ◽  
Odedeyi Peter
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Single Point ◽  
Absolute Error ◽  
Diamond Turning ◽  
Machining Process ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Machining Parameters ◽  
Nose Radius

Abstract The desire for quality infrared lens with better surface finish has brought about the usage of brittle materials like germanium to be machined via a single point diamond turning machining process. However, achieving the required surface finish is complex if special machining techniques and approaches are not employed. In this paper, the effect of two different tool nose radius parameters on surface roughness of single point diamond turned germanium workpiece were studied and analyzed. The machining parameters selected for this experiment were feed, speed and depth of cut. Box-Behnken design was adopted to optimally create a combination of cutting parameters. Measurement of surface roughness after each run in both experiments was achieved using a Taylor Hobson PGI Dimension XL surface Profilometer. The resulting outcomes show that at most experimental runs, the surface roughness value decreased with an increase in nose radius. Mean absolute error was also used to compare the accuracy validation of the two models.

Prediction of Surface Finish and Optimization of Machining Parameters in Turning

2012 ◽  
Vol 463-464 ◽  
pp. 679-683
Author(s):  
Devi Prasad ◽  
Prasad Krishna ◽  
Shrikantha Rao
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Validity And Reliability ◽  
Nose Radius ◽  
Radial Acceleration ◽  
Feed Forward Back Propagation ◽  
Taguchi Design Of Experiments

Surface roughness plays a crucial role in the functional capacity of machined parts. In this work, experiments were carried out on a conventional lathe for different cutting parameters namely feed, spindle speed, depth of cut and tool nose radius according to Taguchi Design of Experiments. Radial acceleration readings were taken with an accelerometer. Optimum cutting parameters and their level of significance were found using Taguchi analysis (ANOVA). Regression analysis was carried out to identify whether the experimental roughness values have fitness characteristic with the process parameters. Recurrence Plots (RP) were obtained using the sensor signals which determine surface roughness qualitatively and Recurrence Quantification Analysis (RQA) technique was used to quantify the RP obtained. Surface finish was predicted using a feed forward back propagation neural network with RQA parameters, cutting parameters and acceleration data as inputs to the network. The validity and reliability of the methods were verified experimentally.

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