scholarly journals Investigation of Surface Quality of CoCrMo Alloy Used in the Tibial Component of the Knee Prosthesis According to the Methods of Turning and Turning-Grinding

2019 ◽  
Vol 26 (1) ◽  
pp. 41-48
Author(s):  
Erkan BAHÇE ◽  
M. Sami GÜLER ◽  
Ender EMİR
Keyword(s):  
Surface Quality ◽  
Tibial Component ◽  
Thermal Stresses ◽  
Knee Prosthesis ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Cocrmo Alloy ◽  
Grinding Method

CoCrMo alloys, which are well-known Co-based biomedical alloys, have many different types of surface integrity problems reported in literature. Residual stresses, white layer formation and work hardening layers are some those, matters which occur as a microstructural alteration during machining. Therefore, such problems should be solved and surface quality of end products should be improved. In this paper, the surface quality of CoCrMo alloy used in tibial component of the knee prosthesis produced by means of turning was investigated. An improvement was suggested and discussed for the improvement in their machinability with the developed turning-grinding method. Finite element analyses were also carried out to calculate temperature and thermal stresses distribution between the tool and the tibial component. The results showed that many parameters such as cutting speed, feed rate, depth of cut, tool geometry, and tool wear affect the surface quality of workpieces of CoCrMo alloy. In the turning-grinding method, the machining time is reduced by about six times compared to machining only method. The EDX analysis performed on the surface after machining showed that metal diffusion occurred from tool to the tibial component.

scholarly journals Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates

2016 ◽  
Vol 2016 ◽  
pp. 1-9 ◽  
Author(s):  
M. Nurhaniza ◽  
M. K. A. M. Ariffin ◽  
F. Mustapha ◽  
B. T. H. T. Baharudin
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimal Cutting Parameters ◽  
Cnc End Milling

The quality of the machining is measured from surface finished and it is considered as the most important aspect in composite machining. An appropriate and optimum machining parameters setting is crucial during machining operation in order to enhance the surface quality. The objective of this research is to analyze the effect of machining parameters on the surface quality of CFRP-Aluminium in CNC end milling operation with PCD tool. The milling parameters evaluated are spindle speed, feed rate, and depth of cut. The L9 Taguchi orthogonal arrays, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) are employed to analyze the effect of these cutting parameters. The analysis of the results indicates that the optimal cutting parameters combination for good surface finish is high cutting speed, low feed rate, and low depth of cut.

Study on Identifying Surface Quality of Work Pieces Based on Texture Analysis

2012 ◽  
Vol 201-202 ◽  
pp. 594-597
Author(s):  
Wei Wei Wang ◽  
Dong Hu
Keyword(s):  
Surface Quality ◽  
Surface Texture ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Workpiece Surface ◽  
Quality Of Work ◽  
Short Time

In order to recognize the integrity of workpiece surface texture, this paper introduces the method of mended texture spectrum based on workpiece surface texture. The workpiece surface texture images can be described based on analyzing the influence of cutting parameters on the surface texture. The experimental results indicate that the cutting parameters have a great effect on the integrity of workpiece surface texture. In other words, the effect of cutting speed is evident, that of feed speed, depth of cut to a less extent. In addition, the integrity of texture changes greatly in short time with the increase of cutting parameters.

Influence of Machining Parameters on the Surface Quality of Technical Plastics

2021 ◽  
Vol 105 (1) ◽  
pp. 381-389
Author(s):  
David Dobrocky ◽  
Josef Sedlak ◽  
Zdenek Joska ◽  
Jiri Prochazka ◽  
Zbynek Studeny ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Electrical Engineering ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Thermoplastic Polymer ◽  
Process Fluid ◽  
Electronics And Electrical

The article deals with the evaluation of the influence of conventional methods of machining on the surface quality of selected technical plastics. The thermoplastic polymer polyoximethylene (POM-C) Ertacetal C and polyamide (PA 6) Ertalon 6SA were selected for machining. Both materials are suitable for machining and are used for the production of precision mechanical components (e.g. gears, plain bearings, guides, etc.), but also in electronics and electrical engineering. In all these applications, the quality of machined surfaces is important, especially for functional surfaces that interact with other surfaces. Test specimens from these materials were turned and milled. The technological conditions of machining (revolutions per minute n, cutting speed vc , feed f, depth of cut ap ) were adapted to achieve approximately the same surface roughness values. The milled samples were machined with and without cooling medium (for drought). Turning was performed only dry. As the cutting speed vc increased, the surface roughness of the turned Ertacetal C material decreased, while milling led to a deterioration in the roughness as the cutting speed vc increased. Similar behavior was observed for Ertalon 6SA. The process fluid led to a deterioration in the roughness of the milled surfaces of both plastics. Turned surfaces showed worse roughness than milled surfaces.

Effect of Cutting Parameters on the Quality of the Machined Surface of Cu-Zn-Al Shape Memory Alloy, SMA

2015 ◽  
Vol 1105 ◽  
pp. 93-98
Author(s):  
Adnan I.O. Zaid ◽  
S.M.A. Al-Qawabah
Keyword(s):  
Shape Memory Alloy ◽  
Shape Memory ◽  
Surface Quality ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Direct Extrusion

Shape memory alloys (SMAs) are now widely used in many industrial and engineering applications e.g. in aircrafts, space vehicles, robotics and actuators. However the available literature reveals that little or no work is published on the machinability of these alloys. In this paper, the effect of the main cutting parameters namely: cutting speed, depth of cut and feed rate on the surface quality of the machined surface of the Cu-Zn-Al shape memory alloy both in the cast and after direct extrusion using a CNC milling is investigated. The cutting speed was varied from 750 to 2000 rpm , the depth of cut was varied from 1 to 4 mm and the feed rate was varied from 100 to 250 mm/min. Furthermore, the general microstructure, the mechanical behavior and hardness of the Cu-Zn-Al shape memory alloy both in the cast and after direct extrusion are determined and discussed. It was found that the best achieved surface quality in this SMA, machined within the different investigated cutting conditions is 0.13 microns at cutting speed of 750 rpm, 1 mm depth of cut and 150 mm/min. feed rate, which is better than the surface quality achieved in other materials at the same cutting conditions.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

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).

Thermal hardening and calculation of the mathematical model of face milling of parts made of steel 95X18-Sh to improve the quality of the surface layer

2021 ◽  
pp. 200-206
Author(s):  
I.N. Sedinin ◽  
V.F. Makarov
Keyword(s):  
Mathematical Model ◽  
Cutting Speed ◽  
Physical And Mechanical Properties ◽  
Face Milling ◽  
Experiment Planning ◽  
Depth Of Cut ◽  
Machined Surface ◽  
The Mathematical Model ◽  
Full Factorial

It is considered the complex of operations of the technological process for the heat treatment of steel 95X18-Sh, as a result of which the material of the samples increases the hardness to 59...61 HRC, and also improves the physical and mechanical properties. A full-scale full factorial experiment of face milling of samples was carried out using the method of mathematical planning. In the experiments, a high-precision machine and a carbide cutting tool were used. To calculate the values of the roughness function, the following are taken as independent variables: cutting speed, feed per tooth and depth of cut. In order to determine the coefficients of the linear equation, a central compositional orthogonal plan of the second order for three factors was used. A matrix of levels of variation of independent variable factors and a matrix of experiment planning were compiled. A regression analysis of the obtained experimental statistical data was carried out using the Microsoft Excel, Statistica and Wolfram Alpha programs. As a result of the calculations, a mathematical model of the roughness of the machined surface and optimal cutting conditions were determined.

Fractal-Based Analysis of the Relation Between Surface Finish and Machine Vibration in Milling Operation

2019 ◽  
Vol 19 (01) ◽  
pp. 2050006 ◽  
Author(s):  
Muhammad Owais Qadri ◽  
Hamidreza Namazi
Keyword(s):  
Surface Quality ◽  
Complex Structure ◽  
Vibration Signal ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machine Vibration ◽  
Milling Operation ◽  
Surface Changes

Analysis of surface quality of machined workpiece is an important issue in machining of materials. For this purpose, scientists analyze how the texture of machined surface changes due to different conditions. Machine vibration is one of the factors that highly affects the surface quality of machined surface. In this research, we analyze the relation between machine vibration and surface quality of machined workpiece. For this purpose, we employ fractal theory and analyze how the complex structure of machined surface changes with the complex structure of machine vibration signal in case of variations of machining parameters, namely, depth of cut, feed rate and spindle speed, in milling operation. Based on the results, variations of surface quality of machined workpiece are related with the variations of complexity of machine vibration signal. The method of analysis employed in this research can be applied to other machining operations in order to find the relation between machine vibration and surface quality of machined workpiece.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

scholarly journals Surface Quality Assessment after Milling AZ91D Magnesium Alloy Using PCD Tool

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 617 ◽  
Author(s):  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Operational Parameters

Surface roughness is among the key indicators describing the quality of machined surfaces. Although it is an aggregate of several factors, the condition of the surface is largely determined by the type of tool and the operational parameters of machining. This study sought to examine the effect that particular machining parameters have on the quality of the surface. The investigated operation was the high-speed dry milling of a magnesium alloy with a polycrystalline diamond (PCD) cutting tool dedicated for light metal applications. Magnesium alloys have low density, and thus are commonly used in the aerospace or automotive industries. The state of the Mg surfaces was assessed using the 2D surface roughness parameters, measured on the lateral and the end face of the specimens, and the end-face 3D area roughness parameters. The description of the surfaces was complemented with the surface topography maps and the Abbott–Firestone curves of the specimens. Most 2D roughness parameters were to a limited extent affected by the changes in the cutting speed and the axial depth of cut, therefore, the results from the measurements were subjected to statistical analysis. From the data comparison, it emerged that PCD-tipped tools are resilient to changes in the cutting parameters and produce a high-quality surface finish.

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