A Contribution to the Thermal Field Evaluation at the Tool-Part Interface for the Optimization of Machining Conditions

In this study, an experimental measurement methodology is implemented that allows obtaining consistent temperature data during the turning operation of semi-hard C20 steel using SNMG carbide insert, allowing us to have better control at the tool-part interface. The interactions of the phenomena influencing the cut led our choices on the development of a correlation model for the analysis and prediction of the relationships between the machining parameters by measurement of the temperature. The measurement procedure implemented for the temperature estimate is based on the use of an FLIR A325sc type infrared camera mounted and protected by a device on the machine tool. The Taguchi method was chosen to find the relationships between the input factors (cutting speed (Vc), feed rate (a), depth of cut (p)), and the output factor (temperature (T)). In the future, we will develop a numerical validation model to simulate the machining process in order to predict temperatures

Application of Taguchi and RSM Parameters on Surface Roughness and Material Removal Rate of AA6082T6

Taguchi and Response Surface Methodologies (RSM) for Surface Roughness (SR), and Material Removal Rate (MRR) in end processing of AA6082T6 with tungsten carbide Insert. The Experiments have been driven using the Taguchi plan. The cutting boundaries are feed, speed, and profundity of cut. The impact of machining boundaries and to assessed the ideal cuttings condition to surface unpleasantness and material expulsion rate. A second-request model has been work between the cutting limits and the machining limits to recognize out the SR and MRR by using reaction surface strategy. The test outcomes have shown the most basic factor in the surface unpleasantness is speed (31.068%) and in the material evacuation rate is profundity of cut (51.9404%). The anticipated qualities are affirmed by utilizing affirmation tests.

Analysis the effect of cutting speed on wear and crystal structure on CVD and PVD layer carbide insert materials

It has been done analysis effect of cutting speed on wear and crystal structure on CVD and PVD layer carbide inserts has been performed. The purpose of the study was to determine the effect of cutting speed on wear, crystal size, dislocation density and micro lattice strain on CVD and PVD layer carbide insert materials to cut the AMS5643 stainless steel material. CVD and PVD layer carbide insert cutting process with cutting speed variation 113; 126; 140; 175 m/min with cutting motion of 0.38 mm/round and depth of cut 1.5 mm fixed. Wear test results showed that CVD layer carbide insert wear was 15% higher than PVD layer carbide inserts. The results showed that the size of CVD layer carbide insert crystals was smaller than PVD layer carbide inserts by 42% and the dislocation density of CVD layer carbide inserts made no significant difference to PVD layer carbide inserts, as well as micro lattice strains for CVD layer carbide inserts greater than PVD layer carbide inserts.

Characteristics of dimple structure on aluminium silicon alloy fabricated using turning machine

Purpose This research aims to present the characteristics of dimple structure which was fabricated using a turning machine, where the characteristics include sizes, shapes, area ratio and aspect ratio. This research aims at filling the gap in the machining parameters of previous research in producing dimple by using turning process with the aid of dynamic assisted tooling for turning (DATT). In producing dimple, a carbide insert grade H1 was used on a hypereutectic aluminium silicon alloy (A390) material. Dimple has many advantages such as for reducing friction coefficient, load-carrying capacity and trap wear debris for sliding mechanical components. Design/methodology/approach There are seven machining parameters (cutting speed, feed rate, depth of cut, frequency, amplitude, rake angle, relief angle and nose radius) which have an influence on dimple produced. Taguchi method (orthogonal arrays L8) was used to conduct the experiment systematically and efficiently for these seven parameters. A carbide insert grade H1 was used as a cutting tool on a turning machine with the aid of DATT. The dimple structure was fabricated on a cylindrical rod hypereutectic aluminium silicon alloy (A390). A profilometer 3D Alicona infinite focus and an optical microscope equipped with Vis software were used to analyse the fabricated dimple structure. Findings Various shapes and sizes of ellipse dimples were produced in this research, including short and long drops with lengths in the range of 517.03–3,927.61 µm, widths of 565.15–1,039.19 µm, depths of 14.46–124.87 µm, area ratios of 5.05–25.65% and aspect ratios of 0.007%–0.111%. There were four experiments within the optimal area ratio range of 10%–20%, i.e. the second, third, seventh and eighth experiments. The width of these dimples was 895.95, 961.39, 787.27 and 829.22 µm, length was 826.26, 3163.13, 885.98 and 1026.65 µm, depth was 83.67, 84.19, 87.05 and 110.70 µm and area ratio was 15.12%, 13.14%, 14.79% and 12.70%. The surface roughness of textured surface was below 1 µm. In this research, the results obtained were similar with that of previous researchers on dimple structure related to tribology performance. Originality/value There exists machining parameters, namely, cutting speed and frequency, that were not used by previous research in producing dimple. These machining parameters (cutting speed and frequency) were used in this research to produce dimple via turning process with the aid of DATT using carbide insert grade H1. The turning process is an environmentally friendly process which is suitable for mass production for fabricating dimple structure as compared to most of the current methods which are widely used in fabricating dimple structure.