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1
Gostimirović, Marin, Dragan Rodić, Milenko Sekulić, and Andjelko Aleksić. "An Experimental Analysis of Cutting Quality in Plasma Arc Machining." Advanced Technologies & Materials 45, no. 1 (October 1, 2020): 1–8. http://dx.doi.org/10.24867/atm-2020-1-001.
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Plasma arc cutting (PAC) is an unconventional process widely used in manufacturing of heavy plate products. This work reports on the research results of machining quality of the workpiece in the plasma arc cutting on the low carbon low alloy steel. An experimental investigation of the characteristics of machining accuracy and surface integrity was carried out for basic machining parameters (cutting speed, arc current, arc voltage, plasma gas pressure, stand-off distance and nozzle diameter). The kerf geometry was determined with three accuracy parameters (top kerf width, bottom kerf width and kerf taper angle). The parameters of deviation present due to plasma curvature were defined by drag and pitch of drag line. The surface roughness was determined with two main roughness parameters through scanning the surface topography (roughness average and maximum height of the profile). The surface properties were determined over microstructure in heat affected zone (HAZ). The results show an acceptable machining quality of the PAC, so that this process is an excellent choice for fast and efficient material removal. However, the plasma arc cutting is not suitable for the final machining because of the metallurgical variations in the HAZ.
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Singh, Kanwal Jeet, Inderpreet Singh Ahuja, and Jatinder Kapoor. "Experimental Investigation and Study the Effect of Hydro Fluoric Acid in Ultrasonic Machining of Polycarbonate Bullet Proof UL-752 and Acrylic Heat Resistant BS-476 Glass." Advanced Engineering Forum 24 (October 2017): 24–39. http://dx.doi.org/10.4028/www.scientific.net/aef.24.24.
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The main objective of this experimental work is to study the effect of Hydro Fluoric acid in ultrasonic machining of polycarbonate bullet proof UL-752 and Acrylic Heat resistant BS 476 Glass. In which, mixture of abrasive particle are also used as the input machining parameter. Three types of abrasive; Alumina, Silicon Carbide and Boron Carbide are used for machining. Experiment has been performed with 8mm of high carbon high chromium tool steel (D2), high carbon steel (HCS) and high speed tool steel (HSS) tools. The material removal rate was father enhanced by HF acid. The experimentation date represent the main effect plots for tool wear rate and material removal rate. After analysis, results reveals that Al2O3+SiC+B2C mixed slurry (1:1:1), Hydro Fluoric acid with 1% concentration and High Speed tool Steel material produce the higher material removal affect.
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Kumar, Sandeep, Bedasruti Mitra, and Naresh Kumar. "Application of GRA method for multi-objective optimization of roller burnishing process parameters using a carbide tool on high carbon steel (AISI-1040)." Grey Systems: Theory and Application 9, no. 4 (October 14, 2019): 449–63. http://dx.doi.org/10.1108/gs-03-2019-0006.
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Purpose The purpose of this paper is to analyze and optimize the roller burnishing process parameters using the design of experiments and grey relational analysis (GRA). Design/methodology/approach In this experimental work, the carbide burnishing tool has been selected for the machining of AISI-1040 high carbon steel to get better product quality and satisfactory machining characteristics. The material surface condition while machining, burnishing tool speed, feed rate, depth of penetration and No. of passes have been selected as process constraints to conduct experimental trials. Findings The surface roughness (SR) and surface hardness were considered as output responses. The experimental outcomes optimized by multi-parametric optimization showed considerable improvement in the process. The roller speed and number of passes are the most significant parameters for surface hardness, whereas the surface condition and roller penetration depth have the most significance on SR. Research limitations/implications The GRA method shows the 0.03376 improvement in grey relational grade between the experimental values and the predicted values. Practical implications The experimental outcomes optimized by multi-parametric optimization showed the considerable improvement in the process and will facilitate steel industries to enhance and improve productivity while burnishing high carbon steel (AISI-1040). Originality/value This research represents valid work, and the authors have no conflict of interests.
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Agarwal, A., M. T. Letsatsi, O. M. Seretse, and R. Marumo. "Experimental thermal analysis and modelling of single point lathe cutting tools without cooling effect." International Journal of Engineering & Technology 7, no. 2 (March 13, 2018): 276. http://dx.doi.org/10.14419/ijet.v7i2.9788.
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This study investigated the use of tungsten carbide tool and high speed steel (HSS) tool when machining aluminum and mild steel. The parameters such as feed and speed of rotation were varied in order to observe their effect on machining operation. The experiments were performed without a coolant. FLIR thermo Cam P60 and Infra-Red Camera were used to record the observations. The highest temperature were recorded when feed rate was 2 mm. A comparison of experiments shows that HSS tooling produced high temperatures when machining mild steel. At 625 rev/min HSS failed when cutting mild steel at 2 mm feed rate. It was generally observed that temperatures generated between a tool and work piece is a function of feed rate, speed of rotation and tool material. These observations can aid the selection of a tool before a machining operation.
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Ramji, B. R., H. N. Narasimha Murthy, and B. K. Deepak. "Performance Analysis of Cryogenically Treated HSS Profile Cutter by Experimental and FEA." Advanced Materials Research 816-817 (September 2013): 311–16. http://dx.doi.org/10.4028/www.scientific.net/amr.816-817.311.
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The main objective of the research was to study the effect of cryogenic treatment and double tempering on the tool life of HSS profile cutter in machining EN47 Spring Steel cutting tool components. TiAlN coated HSS profile cutters were cryogenically treated at-175 °C and double tempered at 200 °C. Milling exercises were carried out using un-treated and treated and double tempered tools on EN-47 spring steel reamer components at different machining conditions. The treated HSS profile cutter showed 40 % greater tool life than that of the un-treated in machining EN-47 spring steel components for making flutes. FEA for temperature profile of the cutting tools of the treated and non-treated was performed. Tool tip temperature for untreated and treated were found to be 22 °C and 20 °C respectively.
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Singh, Kanwal Jit. "Optimization of process parameters of powder mixed EDM for high carbon high chromium alloy steel (D2 steel) through GRA approach." Grey Systems: Theory and Application 8, no. 4 (October 8, 2018): 388–98. http://dx.doi.org/10.1108/gs-01-2018-0001.
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Purpose The purpose of this paper is to investigate the process parameters and optimise the machining input parameter of powder mixed electric discharge machining for high carbon high chromium alloy steel (D2 steel) for the industrial application. Grey relational analysis approach has been used to obtain the multiple performance output response. Design/methodology/approach In this experimental work, input parameters, namely, pulse on-time, discharge current, tool material and grit size, are selected. The design of the experiment has been constructed with the help of MINITAB 7 Software, in which L16 orthogonal array has been preferred for the experimentation. The effect of input parameters, namely, material removal rate, tool wear rate and surface roughness, is investigated. Grey relational analysis and analysis of variance are performed to optimise the input parameters and better output results. Findings In this experimentation, there is an increment of tool wear rate by 64.49 per cent, material removal rate by 47.14 per cent and surface roughness by 35.82 per cent. Practical implications A lot of practical applications have been found in many different material processing industries like metallurgy, machinery, electronics, transportation, military science, agricultural machinery, etc. These practical applications have brought forward definite and noticeable economic benefits. Originality/value The reader is given a general overview on the machining investigation and optimisation of processes parameters through the grey theory approach. It gives a new framework to investigate the problems where multiple input machining variable and various output responses are obtained in single optimised parameters.
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Teixidor, Daniel, I. Ferrer, and Joaquim de Ciurana. "Experimental Analysis of Laser Micro-Machining Process Parameters." Materials Science Forum 713 (February 2012): 67–72. http://dx.doi.org/10.4028/www.scientific.net/msf.713.67.
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This paper reports the characterization of laser machining (milling) process to manufacture micro-channels in order to understand the incidence of process parameters on the final features. Selection of process operational parameters is highly critical for successful laser micromachining. A set of designed experiments is carried out in a pulsed Nd:YAG laser system using AISI H13 hardened tool steel as work material. Several micro-channels have been manufactured as micro-mold cavities varying different process parameter. Results are obtained by evaluating the dimensions and the surface finish of the micro-channel. The dimensions and shape of the micro-channels produced with laser-micro-milling process exhibit variations. In general the use of low scanning speeds increases the quality of the feature in both surface finishing and dimensional.
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Krishna Sastry, K. V., V. Seshagiri Rao, M. S. Kumar, and A. Velayudham. "Experimental Analysis of Hole Ovality in Drilling of Carbon-Carbon Composites." Applied Mechanics and Materials 592-594 (July 2014): 294–301. http://dx.doi.org/10.4028/www.scientific.net/amm.592-594.294.
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The Carbon-Carbon (C-C) composite materials are logical candidates for the manufacture of space crafts and other advanced structures, due to their low density values. These materials are naturally expensive, and the machining cost increases the final product’s price. The literature availability on the machining, particularly with reference to drilling operation of these materials is very rare. Hence an experimental investigation has taken to study the hole quality of this ubiquitous carbon-carbon composite material. This paper presents a comprehensive analysis about the influence of process parameters on the ovality of the carbon-Carbon composite plate, which is measured with a coordinate measuring machine. The drilling experiments were carried with two different tools like HSS and TiN coated Carbide materials on a CNC drilling machine. The Point Angle, spindle speed and feed rate were chosen as process parameters, and their impact on the quality of drilled hole was analyzed with the help of Taguchi’s orthogonal array and ANOVA-TM software. A comparison was done between the performances of drilling by these two different tools.
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Rajmohan, T., S. D. Sathishkumar, K. Palanikumar, and S. Ranganathan. "Modeling and Analysis of Cutting Force in Turning of AISI 316L Stainless Steel (SS) under Nano Cutting Environment." Applied Mechanics and Materials 766-767 (June 2015): 949–55. http://dx.doi.org/10.4028/www.scientific.net/amm.766-767.949.
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Nano Cutting fluids play a significant role in machining operations and impact shop productivity, tool life and quality of work. In the present work, machining performance of AISI 316L Stainless steel (SS) is assessed under nano cutting environment. Experiments are performed by plain turning of 80mm diameter and 300mm long rod of AISI 316L SS on NAGMAT centre lathe under wet machining with and without Multi Wall Carbon nano Tubes (MWCNT) inclusions in the conventional lubricant. The Second order quadratic models were developed to predict cutting forces using response surface methodology (RSM) based D-optimal design. Machining parameters such as speed, feed rate and depth of cut are chosen as numerical factor, and the wt % of MWCNT content is considered as the categorical factor. Furthermore, using analysis of variance method, significant contributions of process parameters have been determined. Experimental results reveal that wt % of MWCNT and feed rate are the dominant variables on responses.
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Hamood, Sami A., and Vian N. Najm. "Optimization of Plasma Cutting Parameters on Dimensional Accuracy and Machining Time for Low Carbon Steel." Engineering and Technology Journal 38, no. 8A (August 25, 2020): 1160–68. http://dx.doi.org/10.30684/etj.v38i8a.1151.
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This work aims to study the influence of plasma arc cutting parameters on dimensional accuracy and machining time for mild steel (1010) material with the thickness (4 mm). Selected three cutting parameters (arc current, cutting speed, and arc distance) or the experimental work. 12 tests have been performed at each test one parameter has been changed with four various levels and other parameters are constant. The influence of the cutting parameters on response results (dimensional accuracy and machining time) have been studied and analyzed by using response surface methodology (RSM) using the second-order model and main effect plot have been generated of each parameter on response results by using ANOVA depended on results of response surface analysis. The results of the response surface analysis showed that the important influencing parameters on dimensional accuracy were cutting speed and arc current as well as on deviation of dimensional accuracy, and the machining time is further affected with the current more than the cutting speed and the standoff distance. The outcomes of response surface analysis showed that the optimal setting of the cutting parameters to obtain at high dimensional accuracy were (arc current= 110 A, cutting speed = 4000 m/min, arc distance = 2mm) and to obtain on less machining time was (arc current= 110 A, cutting speed = 4000 m/min, arc distance = 5mm).
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Naerheim, Yngve, Tennyson Smith, and Ming-Shong Lan. "Experimental Investigation of Cutting Fluid Interaction in Machining." Journal of Tribology 108, no. 3 (July 1, 1986): 364–67. http://dx.doi.org/10.1115/1.3261205.
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Scanning Auger analysis of fracture surfaces of chips from cutting 4340 steel bars and 4130 steel tubing using CCl4 as a model cutting fluid provide evidence that it is possible for cutting fluid or vapor to penetrate into the chip along fissures created during chip formation. Similar analysis of the rake face on the tools provide evidence of partial penetration between the tool and chip as well. The effect of the penetration is to reduce the energy required for the cutting process by facilitating the chip formation and reducing the adhesion forces between the tool and chip. The penetration can be explained by the capillary action of fissures that provide reactive surfaces and fast propagation paths for the cutting fluid and vapor.
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Rajmohan, T., S. D. Sathishkumar, and K. Palanikumar. "Experimental Investigation of Machining Parameters during Turning of AISI 316L Stainless Steel Using Nano Cutting Environment." Applied Mechanics and Materials 787 (August 2015): 361–65. http://dx.doi.org/10.4028/www.scientific.net/amm.787.361.
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In modern machining processes, there are continuous cost pressures and high quality expectations in the product. Hence, it is required to explore the techniques that can reduce the cost and also increase the quality of the product. In the present work, machining performance of AISI 316L SS is assessed by the performing turning operation under nano cutting environment. Experiments have been carried out by plain turning of 48mm diameter and 600mm long rod of AISI 316L stainless steel on all geared lathe at different cutting velocities and feeds under wet machining with and without Carbon nano Tubes (CNT) inclusions using carbide inserts. The effect of cutting speed, feed rate, depth of cut on tool chip interface temperature and surface roughness are analysed using Taguchi method. Furthermore, using analysis of variance method, significant contributions of process parameters have been determined. Experimental results reveal that feed rate and cutting speed are the dominant variables on responses.
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Geethapriyan, T., and K. Kalaichelvan. "Experimental Investigation of Electrochemical Micromachaning Process Parameters on Pure-Titanium Using Taguchi-Grey Relational Analysis." Applied Mechanics and Materials 852 (September 2016): 198–204. http://dx.doi.org/10.4028/www.scientific.net/amm.852.198.
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Non-conventional machine are nowadays plays a vital role in manufacturing complex shaped products and to produce the product with high accuracy the electrochemical machining is widely used to machine complicated shapes for electrically conducting difficult-to-machine materials such as super alloys, Ti-alloys, alloy steel, tool steel, stainless steel, etc. such titanium-based alloys are in common use for aero engine components such as blades and blisks (blade integrated disks). Therefore, in this present work to investigate the influence of some predominant electrochemical process parameters such as applied voltage, electrolyte concentration, Micro-tool feed rate and duty cycle on the metal removal rate , overcut and surface roughness to fulfill the effective utilization of electrochemical machining of Pure-titanium. The purpose of this study is to investigate the influence of process parameters on machining characteristics and optimize the combination of those parameters using Taguchi-grey relational analysis. From this result, it is observed that process parameters have significant role in Electrochemical Micromachining process and the optimization values has been found using proposed multi-response methodology.
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Shukla, Rahul, and Brajesh Kumar Lodhi. "Experimental Analysis of Machining Parameters in WEDM of AISI D3 Steel Using Taguchi Method." Applied Mechanics and Materials 799-800 (October 2015): 343–50. http://dx.doi.org/10.4028/www.scientific.net/amm.799-800.343.
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Wire Electric Discharge Machining (WEDM) is a non-traditional process of material from conductive material to produce parts with intricate shape and profiles. In the present work, an attempt has been made to optimization the machining conditions for maximum material removal rate, minimise kerf width based on (L9 Orthogonal Array) Taguchi method. Experiments, based on Taguchi’s parameters design, were carried out to effect of machining parameters, like pulse-on-time (TON), pulse-off-time (TOFF), peak current (IP), and wire feed (WF) on the material removal rate and kerf width. The importance of the cutting parameters on the cutting performance outputs is determined by using the variance analysis (ANOVA). The variation of MRR and kerf width with cutting parameters is modeled by using a regression analysis method.
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Srithar, A., K. Palanikumar, and B. Durgaprasad. "Experimental Investigation and Analysis on Hard Turning of AISI D2 Steel Using Coated Carbide Insert." Advanced Materials Research 984-985 (July 2014): 154–58. http://dx.doi.org/10.4028/www.scientific.net/amr.984-985.154.
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Hard turning is one of the important operations for hardened steels and it has more benefits than grinding such as cycle time, process flexibility, and better surface finish at significantly better material removal rate and lesser environment issues. Although the machining process is performed with low feed rate and depths of cut, it results lesser machining time as compared with conventional turning. This paper discusses the machining performance tests on the AISI D2 hardened steel to 64 HRC were carried out using chemical vapor deposition ( cvd) coated carbide insert. Experiments are carried out on lathe using the cutting conditions prefixed. The responses studied in the investigation are cutting forces (fx, fy, and fz) and. The cutting parameters considered for the investigation are feed rate, depth of cut and cutting speed. The performance of machining parameters on response is studied and presented in detail. In chip morphology study results different formation and types of chips operating under various cutting conditions.
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Kumar, Santosh, Mohammed Riyaz Ahmed, Lokesha M, and Manjunath LH. "Investigation of machinability characteristics on C45 steel with cryogenically treated M2 HSS tool using statistical technique." International Journal for Simulation and Multidisciplinary Design Optimization 10 (2019): A5. http://dx.doi.org/10.1051/smdo/2019006.
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The machining industries always eye on increasing hardness and reducing the friction at the cutting tool–workpiece interface to reduce flank wear, thereby enhancing the tool life. The present study investigates the effect of deep cryogenic treatment (DCT) on the behavior of M2 HSS tool in turning of C45 medium carbon steel. The tool is double tempered and is tested for hardness and flank wear. The power consumption is also analyzed in the process with a focus on green machining. While Taguchi's L 27 orthogonal array (OA) is used to study the main interaction effect of all machining parameters, analysis of variance (ANOVA) and signal to noise (S/N) ratio are used for analysis of experimental outcomes. The study reveals that DCT has enhanced the hardness of HSS tool by 14.9%, while speed and feed were the dominating factors on the flank wear. Microstructure morphology using SEM is also discussed.
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Isobe, Hiromi, Yusuke Uehara, Keisuke Hara, Takashi Onuma, and Arata Mihara. "Experimental Verification of Machining Process of Ultrasonic Drilling." Key Engineering Materials 516 (June 2012): 275–80. http://dx.doi.org/10.4028/www.scientific.net/kem.516.275.
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Drill processing of difficult-to-cut materials such as ceramics, hardened steel, glass and heat-resistant steel is widely required in the industrial world. Furthermore the drilling process becomes more and more difficult in the case of hole diameters less than one millimetre. In order to achieve the requirements for the drilling process, ultrasonically assisted machining is applicable. Ultrasonic vibration assisted machining techniques are suitable for machining difficult-to-cut materials precisely. However, the cutting process of ultrasonic drilling has not been clarified. It is difficult to observe directly the effect of vibration. The aim of this study is to observe the dynamic, instantaneous and micro cutting process. In this report, a high-speed camera with a polarized device, which is appropriately arranged, realized the visualization of the process of ultrasonic drilling based on photoelastic analysis. For conventional drilling, the stress distribution diagram showed that the intensive stress occurred in limited areas under the chisel because the chisel edge of the drill produces large plastic deformation. On the other hand, the ultrasonic drilling produced spread stress distribution and a stress boundary far away from the chisel. The photoelastic analysis showed the explicit difference of drilling processes.
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Kumar, R., A. Modi, A. Panda, A. K. Sahoo, A. Deep, P. K. Behra, and R. Tiwari. "Hard Turning on JIS S45C Structural Steel: An Experimental, Modelling and Optimisation Approach." International Journal of Automotive and Mechanical Engineering 16, no. 4 (December 30, 2019): 7315–40. http://dx.doi.org/10.15282/ijame.16.4.2019.10.0544.
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The present research is performed while turning of JIS S45C hardened structural steel with the multilayered (TiN-TiCN-Al2O3-TiN) CVD coated carbide insert by experimental, modelling and optimisation approach. Herein, cutting speed, feed rate, and depth of cut are regarded as input process factors whereas flank wear, surface roughness, chip morphology are considered to be measured responses. Abrasion and built up-edge are the more dominant mode of tool-wear at low and moderate cutting speed while the catastrophic failure of tool-tip is identified at higher cutting speed condition. Moreover, three different Modelling approaches namely regression, BNN, and RNN are implemented to predict the response variables. A Back-propagation neural network with a 3-8-1 network architecture model is more appropriate to predict the measured output responses compared to Elman recurrent neural network and regression model. The minimum mean absolute error for VBc, Ra and CRC is observed to be as 1.36% (BNN with 3- 8-1 structure), 1.11% (BNN with 3-8-1 structure) and 0.251 % (RNN with 3-8-1 structure). A multi-performance Optimisation approach is performed by employing the weighted principal component analysis. The optimal parametric combination is found as the depth of cut at level 2 (0.3 mm)-feed at level 1 (0.05 mm/rev) – cutting speed at level 2 (120 m/min) considered as favourable outcomes. The predicted results were validated through a confirmatory trial providing the process efficiency. The significant improvement for S/N ratio of CQL is observed to be 9.3586 indicating that the process is well suited to predict the machining performances. In conclusion, this analysis opens an avenue in the machining of medium carbon low alloy steel to enhance the machining performance of multi-layered coated carbide tool more effectively and efficiently.
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Ku, Wei Liang, Han Ming Chow, Yao Jang Lin, Der An Wang, and Lieh Dai Yang. "Optimization of Thermal Friction Drilling Using Grey Relational Analysis." Advanced Materials Research 154-155 (October 2010): 1726–38. http://dx.doi.org/10.4028/www.scientific.net/amr.154-155.1726.
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The main purpose of this research is to study the optimal machining parameters for a novel process of thermal friction drilling on SUS 304 stainless steel. The experiments were conducted according to an L9 orthogonal array based on Taguchi experimental designs method, and the multiple performance characteristics correlated with surface roughness (SR) and bush length (BL) was investigated by grey relational analysis systematically and comprehensively. Moreover, the significant machining parameters that most intensively affected the multiple performance characteristic and the optimal combination levels of machining parameters associated with the thermal friction drilling on SUS 304 stainless steel were determined through the analysis of variance (ANOVA) and the response graph of grey relational grade. The main machining parameters of the thermal friction drilling such as friction angle, friction contact area ratio, feed rate, and drilling speed were selected to evaluate the effects on SR and BL. The experimental results show that the thermal friction drilling revealed beneficial effects on SR and BL for drilling processes. Moreover, the optimal machining parameters for multiple performance characteristics associated with SR and BL were attained. The developed thermal friction drilling avoids serious tool wears, enhances the surface quality of the machined hole, and prolongs the tool life significantly.
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Patel Gowdru Chandrashekarappa, Manjunath, Sandeep Kumar, Jagadish Jagadish, Danil Yurievich Pimenov, and Khaled Giasin. "Experimental Analysis and Optimization of EDM Parameters on HcHcr Steel in Context with Different Electrodes and Dielectric Fluids Using Hybrid Taguchi-Based PCA-Utility and CRITIC-Utility Approaches." Metals 11, no. 3 (March 4, 2021): 419. http://dx.doi.org/10.3390/met11030419.
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Industries demand stringent requirements towards economical machining without hindering the surface quality while cutting high carbon high chromium (HcHcr) steel. Electrical discharge machining (EDM) of HcHcr steel aims at reducing machining cost (i.e., maximize material removal rate (MRR) and minimize tool wear rate (TWR)) with good surface quality (i.e., minimize surface roughness (SR)). A comparative study was carried out on EDM of HcHcr D2 steel (DIN EN ISO 4957) by applying Taguchi L18 experimental design considering different electrode materials (copper, graphite, and brass), dielectric fluids (distilled water and kerosene), peak current, and pulse-on-time. The process performances were analyzed with respect to material removal rate, surface roughness, and tool wear rate. Pareto analysis of variance was employed to estimate the significance of the process variables and their optimal levels for achieving lower SR and TWR and higher MRR. Hybrid Taguchi-CRITIC-Utility and Taguchi-PCA-Utility methods were implemented to determine the optimal EDM parameters. Higher MRR of 0.0632 g/min and lower SR of 1.68 µm and TWR of 0.012 g/min was attained by graphite electrode in presence of distilled water as dielectric fluid compared to the brass and copper. Additionally, a metallographic analysis was carried out to study the surface integrity on the machined surfaces. Micrographic analysis of the optimal conditions showed lower surface roughness and fewer imperfections (lesser impression, waviness surface, and micro-cracks) compared to worst conditions.
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Krishna Sastry, K. V., and V. Seshagiri Rao. "Multi Response Optimization of Carbon-Carbon (C/C) Drilling Parameters by Using Grey Theory Technique." Advanced Materials Research 936 (June 2014): 1801–8. http://dx.doi.org/10.4028/www.scientific.net/amr.936.1801.
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The objective of this paper is to determine the optimum values of drilling parameters of carbon fibre reinforced carbon (CFRC) composite material with the help of an experimental investigation, which includes the application of unique Grey theory method. The growing application of CFRC composites, which are popularly known as ‘carbon-carbon’ composites in Aerospace, Automobile, Defence and other advanced industries has prompted research studies to develop drilling technology of these special materials. The present work demonstrates the optimization process of multiple responses.The optimum values of drilling characteristics of these composites are calculated by the application of Taguchi method in combination with Grey Relational Analysis technique. The drilling experiments were carried with a High speed steel tool on a plate of carbon-carbon composite material on a CNC Drilling vertical Machining centre.
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Necpal, Martin, and Maroš Martinkovič. "Analysis of Strain in Cutting Zone with FEM and Stereological Metallographic Evaluation." Materials Science Forum 862 (August 2016): 246–53. http://dx.doi.org/10.4028/www.scientific.net/msf.862.246.
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Finite element modelling (FEM) of machining is a widely applied way to get information about the phenomena occurring during the cutting process. This paper discusses experimental work and FEM analysis to investigate the mechanism of CK45 (1.0503) carbon steel chip formation during orthogonal turning process. Local strain in cutting zone is estimated by measurement of deformation of metallographic cut using stereological evaluation of the gain boundary orientation. Estimated local strain in cutting zone was compared to deformation analysis for orthogonal cutting was made, based on simulation results in numerical modelling software DEFORM 2D. Stress, temperature, tool wear is also discussed in the last part of this paper.
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Cheng, Yao Nan, Zhen Jia Li, Jun Gao, and Yong Gang Zhao. "Analysis and Study on Single Physics Field and Coupling Field of Cutting Tools for Machining Carbon Structural Steel." Key Engineering Materials 431-432 (March 2010): 170–73. http://dx.doi.org/10.4028/www.scientific.net/kem.431-432.170.
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Based on the experiments on milling the carbon structural 45 steel with the flat rake milling insert and the waved-edge milling insert, the analysis and study on single physics field and coupling field are studied. On the basis of the milling force and milling temperature mathematical models, the force density function and heat density function of the waved-edge milling insert are built, the stress fields analysis and temperature fields analysis have been done. In order to discuss the distribution principle of equivalent stress and distortion under coupling condition, the coupling analysis on the stress field and temperature field is done. All these studies provide the theoretic and experimental basis for solving the cutter disrepair and groove optimization technology.
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Prabhu, S., and B. K. Vinayagam. "Multiresponse Optimization of Edm Process with Nanofluids Using Topsis Method and Genetic Algorithm." Archive of Mechanical Engineering 63, no. 1 (March 1, 2016): 45–71. http://dx.doi.org/10.1515/meceng-2016-0003.
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Abstract Electrical Discharge Machining (EDM) process with copper tool electrode is used to investigate the machining characteristics of AISI D2 tool steel material. The multi-wall carbon nanotube is mixed with dielectric fluids and its end characteristics like surface roughness, fractal dimension and metal removal rate (MRR) are analysed. In this EDM process, regression model is developed to predict surface roughness. The collection of experimental data is by using L9 Orthogonal Array. This study investigates the optimization of EDM machining parameters for AISI D2 Tool steel using Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method. Analysis of variance (ANOVA) and F-test are used to check the validity of the regression model and to determine the significant parameter affecting the surface roughness. Atomic Force Microscope (AFM) is used to capture the machined image at micro size and using spectroscopy software the surface roughness and fractal dimensions are analysed. Later, the parameters are optimized using MINITAB 15 software, and regression equation is compared with the actual measurements of machining process parameters. The developed mathematical model is further coupled with Genetic Algorithm (GA) to determine the optimum conditions leading to the minimum surface roughness value of the workpiece.
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Sredanovic, Branislav, and Gordana Globocki Lakic. "Experimental Study on Micro-Machinability of Hardened Tool Steel in Profile Micro-Milling." Solid State Phenomena 261 (August 2017): 85–92. http://dx.doi.org/10.4028/www.scientific.net/ssp.261.85.
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Components miniaturization in industry leads to intensive research and development of efficient micro-technologies through research of different production processes, machines and tools. This paper presents experimental research on machinability of inclined surfaces on hardened steel workpieces with long-neck micro-end-ball mills. Workpiece is hardened AISI D2 tool steel (X155CrVMo-5). Micro-parts of this material is usually produced by non-conventional technologies such as electro-discharge machining (EDM) and laser beam machining (LBM), that allows machining of 2D or simple 3D structures. The effects of geometrical and cutting parameters on output machinability parameters in ball micro-milling were evaluated. Analysis of tool deflection, surface roughness and tool wedge wear was performed, in order to obtain the recommended cutting parameters for more precise, accurate and quality of micro-parts.
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Kosit, Khanchai, and Komson Jirapattarasilp. "The Experimental Investigation of WEDM for Surface Roughness of Hardened Tool Steel: SKD 61." Advanced Materials Research 650 (January 2013): 588–92. http://dx.doi.org/10.4028/www.scientific.net/amr.650.588.
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SKD 61 is tool steel that recommended using for hot working as mold and die. . In order to making mold and die, Wire Electrode Discharged Machining (WEDM) has been most operation. The objective of this research was to study factors, which were affected on surface roughness and optimal parameters in WEDM of hardened tool steel. Material used in the experiment was tool steel JIS SKD 61 that was hardening by heat treatment process. Taguchi’s experimental design was conducted on 5 factors and 3 levels that L27 of Taguchi standard orthogonal array was chosen for the design of experiments. Power setting, off time off, wire feeding, wire tension and wire offset were chosen as factor for evaluation surface roughness. The importance level of the machining parameters was determined by analysis of variance (ANOVA). The optimum factors combination was obtained by using the analysis of signal- to-noise (S/N) ratios. Finally, experimentation was carried out an optimal solution of machining parameters for quality of surface roughness in WEDM process.
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Markopoulos, Angelos P., Nikolaos E. Karkalos, Mozammel Mia, Danil Yurievich Pimenov, Munish Kumar Gupta, Hussein Hegab, Navneet Khanna, Vincent Aizebeoje Balogun, and Shubham Sharma. "Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel." Metals 10, no. 12 (December 7, 2020): 1650. http://dx.doi.org/10.3390/met10121650.
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The hardened tool steel AISI O1 has increased strength, hardness, and wear resistance, which affects the complexity of the machining process. AISI O1 has also been classified as difficult to cut material hence optimum cutting parameters are required for the sustainable machining of the alloy. In this work, the effect of feed peer tooth (fz), cutting speed (vc), cutting of depth (ap) on surface roughness (Ra, Rt), cutting force (Fx, Fy), cutting power (Pc), machining cost (Ci), and carbon dioxide (Ene) were investigated during the slot milling process of AISI O1 hardened steel. A regression analysis was carried out on the obtained experimental results and the induction of nonlinear mathematical equations of surface roughness, cutting force, cutting power, and machining cost with a high coefficient of determination (R2 = 90.62–98.74%) were deduced. A sustainability assessment model is obtained for optimal and stable levels of design variables when slot milling AISI O1 tool steel. Stable indicators to ensure personal health and safety of operation, P1 values were set to “1” at a cutting speed of 20 m/min or 43.3 m/min and “2” at a cutting speed of 66.7 m/min or 90 m/min. It is revealed that for eco-benign machining of AISI O1, the optimum parameters of 0.01 mm/tooth, 20 m/min, and 0.1 mm should be adopted for feed rate, cutting speed, and depth of cut respectively.
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Dubovska, Rozmarina, and Jozef Majerik. "Experimental Investigation and Analysis of Cutting Forces When Machining X5CrNi18-10 Stainless Steel." Manufacturing Technology 15, no. 3 (June 1, 2015): 322–29. http://dx.doi.org/10.21062/ujep/x.2015/a/1213-2489/mt/15/3/322.
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Nadolny, K., and W. Kapłonek. "Analysis of Flatness Deviations for Austenitic Stainless Steel Workpieces after Efficient Surface Machining." Measurement Science Review 14, no. 4 (August 1, 2014): 204–12. http://dx.doi.org/10.2478/msr-2014-0028.
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Abstract The following work is an analysis of flatness deviations of a workpiece made of X2CrNiMo17-12-2 austenitic stainless steel. The workpiece surface was shaped using efficient machining techniques (milling, grinding, and smoothing). After the machining was completed, all surfaces underwent stylus measurements in order to obtain surface flatness and roughness parameters. For this purpose the stylus profilometer Hommel-Tester T8000 by Hommelwerke with HommelMap software was used. The research results are presented in the form of 2D surface maps, 3D surface topographies with extracted single profiles, Abbott-Firestone curves, and graphical studies of the Sk parameters. The results of these experimental tests proved the possibility of a correlation between flatness and roughness parameters, as well as enabled an analysis of changes in these parameters from shaping and rough grinding to finished machining. The main novelty of this paper is comprehensive analysis of measurement results obtained during a three-step machining process of austenitic stainless steel. Simultaneous analysis of individual machining steps (milling, grinding, and smoothing) enabled a complementary assessment of the process of shaping the workpiece surface macro- and micro-geometry, giving special consideration to minimize the flatness deviations
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Zou, Ping, Yingshuai Xu, Yu He, Mingfang Chen, and Hao Wu. "Experimental Investigation of Ultrasonic Vibration Assisted Turning of 304 Austenitic Stainless Steel." Shock and Vibration 2015 (2015): 1–19. http://dx.doi.org/10.1155/2015/817598.
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This research study focuses on the experimental analysis of the three-dimensional (3D) surface topography and surface roughness of the workpiece machined with ultrasonic vibration assisted turning (UAT) in comparison to conventional turning (CT). For the challenge that machining difficulties of 304 austenitic stainless steel (ASS 304) and high demands for the machined surface quality and machining precision represent, starting with cutting principle and processing technology, the ultrasonic vibration method is employed to scheme out a machining system of ultrasonic vibration assisted turning (MS-UAT). The experiments for turning the workpiece of ASS 304 are conducted with and without ultrasonic vibration using the designed MS-UAT, and then the 3D morphology evaluation parametersSaandSqare applied to characterize and analyse the machined surface. The experimental results obtained demonstrate that the process parameters in UAT of ASS 304 have obvious effect on the 3D surface topography and surface roughness of machined workpiece, and the appropriate choice of various process parameters, including ultrasonic amplitude, feed rate, depth of cut, and cutting speed, can enhance the machined surface quality efficiently to make the machining effect of UAT much better than that of CT.
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Marimuthu, P., and N. E. Paul Edwin. "Experimental Study for Turning AISI1040 Steel Using TiCN/TiN Coated Tool." Applied Mechanics and Materials 573 (June 2014): 638–43. http://dx.doi.org/10.4028/www.scientific.net/amm.573.638.
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AISI 1040 is a high quality, unalloyed medium carbon steel usually good ductility with resistance to wear. Tool wear (TW) and surface roughness (SR) are mostly considered as demanding phases, and thus causing poor results in machining operations. Optimization of cutting parameter is more crucial at this condition for improving the quality of the product. Taguchi method is the method to achieve a robust experimental design in the study of product quality is an important issue. The best factors/levels combination with lowest societal cost solution to achieve customers requirements look by Taguchi method. Various cutting speed, feed and depth of cut are taken as parameters. In this study single response optimization was performed in computer numerically controlled (CNC) turning AISI1040 with TiCN/TiN coated cutting tool under dry condition using Taguchi Techniques with the objective of minimization SR and TW. Analysis of variance (ANOVA) was used for identifying the significant parameters affecting the responses.
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Karmiris-Obratański, Panagiotis, Nikolaos E. Karkalos, Anastasios Tzotzis, Panagiotis Kyratsis, and Angelos P. Markopoulos. "Experimental Analysis and Soft Computing Modeling of Abrasive Waterjet Milling of Steel Workpieces." MATEC Web of Conferences 318 (2020): 01031. http://dx.doi.org/10.1051/matecconf/202031801031.
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Conventional machining processes such as turning, milling and drilling have long been prominent in the metalworking industry but alternative processes which do not require the use of a cutting tool in order to conduct material removal have also been proven to be sufficiently capable of achieving high efficiency in various cases. In particular, Abrasive Waterjet (AWJ) machining can be regarded as a rather appropriate choice for cutting operations, taking into consideration that it involves no heat affected zones, is able to process all material types and create a variety of complex features with success. In the present work, a comprehensive study on the effect of four process parameters, namely jet traverse speed, stand-off distance, abrasive mass flow rate and jet pressure on the width and depth of machined slots on a steel workpiece is conducted. The results are first analyzed with statistical methods in order to determine the effect and the relative importance of each parameter on the produced width and depth of the slots. Finally, these results are used to develop soft computing predictive models based on Artificial Neural Networks (ANN), which can efficiently relate the process parameters with its outcome.
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Wang, Der An, Yan Cherng Lin, Han Ming Chow, Shih Feng Fan, and A. Cheng Wang. "Optimization of Machining Parameters Using EDM in Gas Media Based on Taguchi Method." Advanced Materials Research 459 (January 2012): 170–75. http://dx.doi.org/10.4028/www.scientific.net/amr.459.170.
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The aim of this study is to investigate the machining characteristics of gas media used in electrical discharge machining (EDM). The process parameters were designed based on Taguchi method to manage the experimental work. The main process parameters such as machining polarity, gas pressure, peak current, pulse duration, type of gas media, and servo reference voltage were adopted to explore their effects on machining performance in terms of material removal rate (MRR) and surface roughness (SR) for SKD 61 tool steel. The experimental observed values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters affecting obviously the machining performance were determined by analysis of variance (ANOVA). The optimal combination level of machining parameter for each machining characteristic was obtained by the S/N ratio analysis according to Taguchi methodology.
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Singh, Kanwal Jit. "Powder mixed electric discharge machining of high-speed steel T1 grade." Multidiscipline Modeling in Materials and Structures 15, no. 4 (July 1, 2019): 699–713. http://dx.doi.org/10.1108/mmms-03-2018-0039.
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Purpose The purpose of this paper is to represent the innovative process of powder-mixed electrical discharge machining of high-speed steel T1 grade and to conduct experimental investigation to optimize the machining parameters associated with multiple performance characteristics using grey relational analysis. The machining of high-speed steel T1 grade via conventional machining is a difficult process. However, it can be easily machined by powder-mixed electric discharge machining. Design/methodology/approach Carefully selected machining parameters give the optimum output results. For experimentation, the following input parameters have been used: pulse on-time, discharge current, tool material and powder concentration. The effects of input parameters, namely, material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR), have been investigated in this research. Findings Grey relational analysis and analysis of variance have been performed to optimize the input parameters for better output response. Optimized results show increment of TWR, MRR and SR, which is 63.24, 52.18 and 42.49 per cent, respectively. Originality/value This research paper will be beneficial for the industrial application. The GRA result gives the better output response.
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Wang, X. Y., S. Q. Pang, and Q. X. Yu. "Experimental Study on Cutting Force in Machining Nickel Base Superalloy." Key Engineering Materials 455 (December 2010): 379–82. http://dx.doi.org/10.4028/www.scientific.net/kem.455.379.
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Studies on cutting force lead an extremely important guiding significance in the actual producing. Nickel base superalloy is widely in the manufacture of components for some important industrial areas, because of their ability to retain high-strength at elevated temperatures. It possesses excellent performance as a class of advanced materials. Because of its very poor machinability, the study on cutting force in machining nickel-based superalloy in the actual production or scientific research is relatively less. In this paper, Author aim at two kinds of typical difficult-to-machining materials nickel base superalloy (GH4169, K24). Contrasting with other typical materials ,such as 45# steel and high strength steel 35CrMnSi，study the law of cutting force effected by cutting parameters under the conditions of turning . Intuitive analysis of cutting force changes with the cutting parameters, as well as these characteristics on three-axis force of each type of material, that is to improve its processability and to provide guidance to actual production has a positive significance.
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Yang, Fa Zhan, Jun Zhao, Cheng Liang Sun, and Guang Yao Meng. "Experimental Investigations of Tool Wear Mechanisms in Machining 1Cr18Ni9Ti Stainless Steel." Advanced Materials Research 97-101 (March 2010): 1858–62. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.1858.
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The purpose of this investigation is to recognize the wear mechanisms of cemented carbide tools in dry hard turning of stainless steel (1Cr18Ni9Ti). From the view point of machining, stainless steels are often considered as poor machinability materials. Turning tests were carried out by using a CA6140 lathe and a cutting force measuring device. For this purpose, both microscopic and microstructural aspects of the tools were taken into consideration. Meanwhile, the cutting forces are also measured in the experiment. The chips were analyzed by scanning electron microscopy. The machinability of 1Cr18Ni9Ti austenitic stainless steels is examined in terms of tool life and cutting parameter presented in this paper. Results show that cutting forces vary greatly with the experimental cutting parameters. Analysis indicated that tool wear mechanisms observed in the machining tests involve abrasion wear, thermal and fatigue shock wear and adhesive wear.
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Markopoulos, A. P., K. Kantzavelos, N. I. Galanis, and D. E. Manolakos. "3D Finite Element Modeling of High Speed Machining." International Journal of Manufacturing, Materials, and Mechanical Engineering 1, no. 4 (October 2011): 1–18. http://dx.doi.org/10.4018/ijmmme.2011100101.
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This paper presents simulation of High Speed Machining of steel with coated carbide tools. More specifically, Third Wave Systems AdvantEdge commercial Finite Element Method code is employed in order to present turning models, under various machining conditions. As a novelty, the proposed models for High Speed Machining of steel are three-dimensional and are able to provide predictions on cutting forces, tool and workpiece temperatures, chip formation, and chip morphology. Model validation is achieved through experimental work carried out under the same conditions as the ones used in modeling. For the experimental work, the principles for design of experiment were used in order to minimize the required amount of experiments and obtain useful results at the same time. Furthermore, a Taguchi analysis is carried out based on the results. The analysis indicates that there is a good agreement between experiment and modeling, and the proposed models can be further employed for the prediction of a range of machining parameters, under similar conditions.
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Prakash, Marimuthu K., Kumar C. S. Chethan, and Prasada H. P. Thirtha. "Residual Stresses Modelling of End Milling Process Using Numerical and Experimental Methods." Materials Science Forum 978 (February 2020): 106–13. http://dx.doi.org/10.4028/www.scientific.net/msf.978.106.
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Machining has been one of the most sort of process for realizing different products. It has significant role in the value additions process. Machining is one of the production process where material is removed from the parent material to realize the final part or component. Among machining, the well known machining processes are turning, milling, shaping, grinding and non-conventional machining processes like electric discharge machining, ultrasonic machining, chemical machining etc. The fundamental of all these processes being material removal in the form of chips using a tool either in contact or not in contact. In the present work, milling is being taken for study Finite element analysis is being used as a tool to understand the different phenomenon that underlies the machining processes. Of late, the machining induced residual stresses is of great interest to the researchers since the residual stresses have an impact on the functional performances. The present work is to model the milling process to predict the forces and residual stresses using finite element method. Unlike many researchers, the authors have attempted to develop oblique cutting model rather than an orthogonal cutting model. The present work was carried out on AISI 1045 steel.
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Elias, Rasha R. "Investigation of the Effect of Nano Powder Mixed Dielectric on EDM Process." Engineering and Technology Journal 38, no. 3A (March 25, 2020): 295–307. http://dx.doi.org/10.30684/etj.v38i3a.337.
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In this paper, Artificial Neural Network was adopted to predict the effect of current, the concentration of aluminum oxide (Al2O3) and graphite Nanopowders in dielectric fluid for the machining of Carbon steel 304 using Electrical Discharge Machining (EDM). The process variables were utilized to find their effect on Material Removal Rate (MRR), Surface Roughness (SR), and Tool Wear Rate (TWR). It was revealed from the experimental work that the addition of aluminum oxide and graphite Nanopowders into dielectric fluid maximizing MRR, minimized the SR and TWR at various variables. Minitab software was used in the design of experiments. Analysis of the process outputs of EDM indicates that graphite powder concentration greatly influencing SR also the discharge current whereas the current and Nanopowders concentration has more percentage of influence on the TWR and MRR.
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Chuang, Fang Pin, Yan Cherng Lin, Han Ming Chow, and A. Cheng Wang. "Optimization of Multiple Performances for EDM in Gas Media Using Grey Relational Analysis." Applied Mechanics and Materials 620 (August 2014): 173–78. http://dx.doi.org/10.4028/www.scientific.net/amm.620.173.
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The aim of this investigation is to optimize the multiple performance characteristics of electrical discharge machining (EDM) for SKD 61 tool steel in gas media using grey relational analysis. The three most important machining characteristics namely material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR) were considered as the measures of the performance characteristics. A series of experiments were conducted according to an L18 orthogonal array based on the Taguchi experimental design method. The observed data obtained from the experiments were evaluated to determine the optimization of machining parameters correlated with multiple performance characteristics through grey relational analysis. Moreover, analysis of variance (ANOVA) was conducted to explore the significant machining parameters crucially affecting the multiple performance characteristics. In addition, the optimal combination levels of machining parameters were also determined from the response graph of grey relational grades for each level of machining parameter.
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Gil, Ruben, J. A. Sánchez, N. Ortega, S. Plaza, B. Izquierdo, and I. Pombo. "Analysis of Micro-Pin Manufacturing Using Inverse Slab Electrical Discharge Milling (ISEDM) Process." Key Engineering Materials 496 (December 2011): 247–52. http://dx.doi.org/10.4028/www.scientific.net/kem.496.247.
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Abstract. This paper analyses the technological capabilities of a novel rotary (EDM) electrical discharge machining process for the manufacturing of high aspect ratio cylindrical micro-components. The process is called Inverse Electrical Discharge Grinding (ISEDM). An experimental analysis has been carried out on high speed steel (tool steel Vanadis 23), using a conventional EDM machine and graphite electrode. The effect of pulse off-time, work piece final diameter and machining length on material removal rate, electrode wear ratio, radial accuracy and surface roughness has been quantified. From the study, optimum strategies that involve the use of different EDM regimes for achieving the optimum requirements can be defined. Micro-pins of 0.3 mm diameter with aspect ratio as high as 100:1 have been successfully manufactured.
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Chen, Cheng Shun, and Chi Hui Huang. "Experimental Study on Five-Axis Machining Parameter for NAK80 Die Steel." Materials Science Forum 594 (August 2008): 226–34. http://dx.doi.org/10.4028/www.scientific.net/msf.594.226.
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The surface quality and contouring accuracy of die cavities directly influences the surface roughness of the products. Different types of complex surfaces of products have become popular in product design in recent years and consequently 5-axis machining techniques become a mainstream in the manufacturing of the die and moulds used in products mentioned above, because of their features and flexibility. This research applies Taguchi method to find out a set of optimal machining parameters in five-axis milling process. The table rotating-tilting type five-axis machine is used to perform the experimental cutting. The cavity of die is modeled as convex half spherical surface, and the material of die is NAK 80 die steel. The four parameters studied are cutting speed, feed rate, tool paths, and contact points, and each of these factors has three levels. The target of this study is the feature of smaller-the-better that is minimization of the surface roughness. The experimental results show that the optimal parameters are moderate cutting speed and contact points, higher feed rate, five-axis tool path. ANOVA analysis indicates that the tool path influences the surface roughness most, which accounts for about 86%. Using optimal parameters to machine a roughly machined concave spherical surface can reach its roughness to 0.234μm, and the roundness error about 0.0314mm. It is believed that the results and method presented in the paper give a good reference for industry applied.
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Kamaraj, Abishek B., and Murali M. Sundaram. "Analytical and Experimental Study of Electrochemical Micromilling." International Journal of Manufacturing, Materials, and Mechanical Engineering 5, no. 2 (April 2015): 1–16. http://dx.doi.org/10.4018/ijmmme.2015040101.
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Electrochemical micromachining (ECMM) is a non-conventional manufacturing method suitable for the production of microsized components on a wide range of conductive materials. ECMM improves dimensional accuracy and simplifies tool design for machining hard, high strength, heat resistant, and conductive materials into complex shapes. Extremely small interelectrode gaps of the order of few microns are required in ECMM for better dimensional accuracy. However, excessively small interelectrode gaps may lead to complications, such as short-circuiting, which disrupt the stability of ECMM process. This necessitates the need for better understanding of the interelectrode gap dynamics. This paper presents a mathematical model for the analysis of interelectrode gap under non-steady state conditions in micromilling of steel using the ECMM process. Experimental verification of the mathematical model was conducted using an in-house built micro electrochemical machining system. The model is capable of predicting the machining results to within 1- 5 µm error (10- 50%).
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Cheng, Yao Nan, Zhen Jia Li, Yong Gang Zhao, and Wei Jun Sun. "Study on Impact Disrepair Mathematic Model and Groove Optimization of Cutting Tools for Machining Carbon Structural Steel." Key Engineering Materials 375-376 (March 2008): 459–64. http://dx.doi.org/10.4028/www.scientific.net/kem.375-376.459.
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Based on the theoretic analysis and experiments on milling the carbon structural 45 steel with the flat rake milling insert and the waved-edge milling insert with complex 3D grooves which is developed by HarBin University of Science and Technology, we have studied on the impact disrepair mathematic model and groove optimization. On the basis of the milling force mathematic model and force density function of the waved-edge milling insert with complex 3D grooves the author built, we have the finite element analysis and blurry synthetical judgement of the 3D stress field, and forecast that the anti-impact disrepair capability of the waved-edge milling insert is choiceness. We find out the difference of the impact disrepair invalidation types between different grooves milling inserts by the experiments. Based on the plentiful and systemic impact disrepair experiments, as the emphasis in this paper, we build the impact disrepair life cumulating distribution function mathematic model by the mathematics statistic method and have contrast analysis of the impact disrepair average lives between the two types of milling inserts, and prove that the anti-impact disrepair capability of the waved-edge milling insert is choiceness. All these studies provide the theoretic and experimental basis for solving the cutter disrepair which is the key problem in the automatization production and groove optimization.
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Kino, Haruki, Takumi Imada, Keiji Ogawa, Heisaburo Nakagawa, and Hitomi Kojima. "An Experimental Investigation on Micro End Milling with High-Speed Up Cut Milling for Hardened Die Steel." Materials 13, no. 21 (October 23, 2020): 4745. http://dx.doi.org/10.3390/ma13214745.
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The importance of micromachining using small diameter end mills and the dies used for them has been increasing in the machining of small parts. However, the reality is that there are various requirements to improve the machining surface, machining accuracy, machining efficiency, and tool life. Therefore, this paper discusses the possibility of satisfying these requirements by high-speed up cut milling in side cutting. The goal of this study was to solve the aforementioned problems, by conducting a detailed analysis of the machining phenomena in order to understand their mechanisms. In particular, the effects of high-speed cutting using a high-speed air-turbine spindle with highly stiff rolling bearings were analyzed. Moreover, cutting experiments were conducted by measuring the cutting force and flank wear of the tool, to reveal the differences in the cutting phenomena relative to the cutting direction in high-speed micro end milling. Description of the machined surface and the measurement of its profile were also included in the discussions. On the basis of the results, high-speed up cut milling is a better choice than down cut milling; furthermore, a high-feed rate further increases machining efficiency and improves tool life.
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Camposeco-Negrete, Carmita, and Juan de Dios Calderón-Nájera. "Optimization of Machining Time and Surface Quality of AISI D2 Tool Steel in WEDM Using Taguchi Methodology and Desirability Analysis." Materials Science Forum 977 (February 2020): 27–33. http://dx.doi.org/10.4028/www.scientific.net/msf.977.27.
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One of the non-conventional machining processes widely used in the industry is the wire electrical discharge machining (WEDM). This process has many advantages, like the great precision and quality that can be achieved. As well as other manufacturing operations, the success of the process relies on a correct selection of the cutting parameters. The present paper outlines an experimental study to optimize the machining time and the surface roughness in WEDM of AISI D2 tool steel during roughing machining. The Taguchi methodology is used to evaluate the effects and contributions of the pulse-on time, pulse-off time, servo voltage, and wire speed, on the response variables. The desirability method is employed to define a set of cutting parameters that allows reducing both machining time and surface roughness at the same time. The pulse-on time is the most significant factor for reducing the machining time, followed by the servo voltage, the pulse-off time and the wire speed. For surface roughness, the pulse-off time is the factor with the greatest influence over the response variable. The results obtained show that the machining time is reduced by 4.65%, and the surface roughness is diminished by 4.60% when compared with the initial values that are commonly used in the machining of AISI D2 tool steel. Therefore, greater production rates can be achieved without compromising the quality of the machined parts.
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Abebe, Girma Seife, and Ping Liu. "Experimental Study of End Milling Force on Manganese Steel." Advanced Materials Research 718-720 (July 2013): 239–43. http://dx.doi.org/10.4028/www.scientific.net/amr.718-720.239.
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Cutting force is a key factor influencing the machining deformation of weak rigidity work pieces. In order to reduce the machining deformation and improve the process precision and the surface quality, it is necessary to study the factors influencing the cutting force and build the regression model of cutting forces. This paper discusses the development of the first and second order models for predicting the cutting force produced in end-milling operation of modified manganese steel. The first and second order cutting force equations are developed using the response surface methodology (RSM) to study the effect of four input cutting parameters (cutting speed, feed rate, radial depth and axial depth of cut) on cutting force. The separate effect of individual input factors and the interaction between these factors are also investigated in this study. The received second order equation shows, based on the variance analysis, that the most influential input parameter was the feed rate followed by axial depth, and radial depth of cut. It was found that the interaction of feed with axial depth was extremely strong. In addition, the interactions of feed with radial depth; and feed rate with radial depth of cut were observed to be quite significant. The predictive models in this study are believed to produce values of the longitudinal component of the cutting force close to those readings recorded experimentally with a 95% confident interval.
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Pandey, Gaurav. "Experimental Study During Electrical Discharge Machining of Reinforced Carbon Fiber Plastic Material." International Journal for Research in Applied Science and Engineering Technology 9, no. 8 (August 31, 2021): 1445–51. http://dx.doi.org/10.22214/ijraset.2021.37589.
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Abstract: The proper selection of machining conditions and machining parameter is an important aspect, before going to machine a carbon-fiber composite material by Die sinking electrical discharge machining (EDM). Because these conditions will determine such important characteristics as; Material removal rate (MRR), Electrode wears rate (EWR), and Surface roughness (R). The purpose of this work is to determine the optimal values of machining parameters of electrical discharge machine, while machining carbon-fiber-composite with copper electrode. The work has been based on the affect of four design factors: pulse current(Ip) supplied by power supply system of electrical discharge machine (EDM), pulse-on-time(TON), gap voltage(Vg) and duty cycle () on such characteristic like material removal rate (MRR), electrode wear rate(EWR), and surface roughness(Ra) on work-piece surface. This work has been done by means of the technique of design of experiment (DOE), which provides us to perform the above-mentioned analysis with small number of experiments. In this work, a L9 orthogonal array is used to design the experiment. The adequate selection of machining parameters is very important in manufacturing system, because these parameters determine the surface quality and dimensional accuracy of the manufactured part. The optimal setting of the parameters are determined through experiments planned, conducted and analyzed using the Taguchi method. It is found that material removal rate (MRR) reduces substantially, within the region of experimentation, if the parameters are set at their lowest values, while the parameters set at their highest values increases electrode wear rate (EWR). Keywords: EDM, Material removal rate, Surface roughness, Tool wear rate,
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Astarita, Antonello, Luca Giorleo, Fabio Scherillo, Antonino Squillace, Elisabetta Ceretti, and Luigi Carrino. "Titanium Hot Stretch Forming: Experimental and Modeling Residual Stress Analysis." Key Engineering Materials 611-612 (May 2014): 149–61. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.149.
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Titanium alloys, due to their high mechanical properties coupled with light weight and high corrosion resistance, are finding a widespread use in the aeronautic industry. The use of titanium in replacing the conventional alloys, such as aluminum alloys and steel, is reduced by both the high cost of the raw material (it costs anywhere from 3 to 10 times as much as steel or aluminium) and the machining costs (at least 10 times that to machine aluminium). For such a reason new technologies have been studied and developed. In particular many researchers are searching for technologies, such as the precision hot forming, that allows to obtain components with a low buy to fly ratio. Many of the airframe component structures are designed to fit against the inside radius of the fuselage curvature. By combining traditional stretch forming technology with hot titanium forming techniques, the HSF guarantees a saving in material and machining time, which are two serious cost issues for todays aircraft manufacturers. In addition, the process allows for consistent quality in a productively efficient manner, assuring the sustainable attainment of delivery and build schedules. In order to develop and improve the HSF process a modeling of the process itself was executed in order to study the stresses and strains undergone by the material among the deformation. The FEM model was validated through the residual stresses, and in particular the residual stresses provided by the model were compared with the ones experimentally measured using the hole drilling technique. Good agreement, in terms of stress range, was recorded both for the maximum and the minimum stress.
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Tayade, Raju Mahadeorao, Biswanath Doloi, Biplab Ranjan Sarkar, and Bijoy Bhattacharyya. "Experimental Investigation Into Sequential Micro Machining (SMM) for Micro Hole Drilling on SS–304." International Journal of Manufacturing, Materials, and Mechanical Engineering 9, no. 4 (October 2019): 1–16. http://dx.doi.org/10.4018/ijmmme.2019100101.
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Sequential micro machining (SMM) is a strategy of machining applied for micro-part manufacturing. Due to the finding of new sequential machining combinations, the authors have presented a novel combination of micro-ECDM (µECDM) drilling and micro-ECM (µECM) finishing for producing micro-holes in SS-304 stainless steel. An experimental setup was developed indigenously to conduct both machining processes at one station. The sequential processes were employed with desirable machining parameters, during their individual execution. The most desirable parameter like machining voltage, for hole drilling by µECDM was decided by studying hole taper angle, radial overcut, etc. The µECDM generates a recast layer, to overcome the adverse effects of µECDM, with the µECM finishing applied subsequently. The experimental results of SMM indicate a reduction in hole taper angle, improved circularity, and better surface quality. The change of phase of material due to sequencing of µECDM and µECM processes was analyzed by an XRD analysis of SS-304.