Abstract
The main objective of the study is to analyze the various cutting parameters to investigate the surface quality of the minor scale diameter of magnesium alloy in the dry turning process using a different tool nose radius (r). The surface roughness (Ra) was gauged, and micro-images produced by scanning electron microscopy (SEM) were reviewed to evaluate the machined surface topography. The analysis of variance (ANOVA), linear regression model and signal-to-noise (S/N) ratio were applied to investigate and optimize the experimental conditions for surface roughness. The study results imply that the feed rate and tool nose radius significantly affected the surface quality, but the spindle speed did not. The linear regression model is valid to forecast the surface roughness. The cutting parameters for optimum surface quality are a combination of a spindle speed of 710 rpm, a feed rate of 0.052 mm/rev and a tool nose radius of 1.2 mm. The machined surface topography contains the feed marks, micro-voids, material side and material debris, but they become smaller and decrease at a lower feed rate, larger tool nose radius and higher spindle speed. These results show the good surface quality of magnesium alloys in a dry turning process, which could be applied in implant, orthopedic and trauma surgery.
Highlights
Magnesium (Mg) alloys are broadly applied in various applications such as automotive, electronics, medicine, sports and household equipment
The general trend is that the values of surface roughness (Ra) slightly changed with the change of spindle speed (N)
From the feed rate of 0.209 mm/rev, the surface roughness (Ra) increased with an increase in the spindle speed (N). These results have a similar trend compared with the study by Sahithi [25], which reported that the best surface finish was machined at the lowest spindle speed (500 rpm)
Summary
Magnesium (Mg) alloys are broadly applied in various applications such as automotive, electronics, medicine, sports and household equipment. The advantages of this lightweight material include good castability and damping capacity, high specific strength and thermal conductivity, etc. The utilization of magnesium in medical applications (implant, orthopedic and trauma surgery) has significantly increased because it shows promise as a biodegradable metallic material for use in the human body [5,6,7]. The machined surface quality of magnesium plays a critical role in bone surgery (bone repair). The machined surface quality of magnesium alloy needs investigation and analysis to improve its application performance
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