Effect Of Machining Parameters Research Articles

An integrated approach for machining characteristics optimization of polymer nanocomposites

Abstract This paper contrasts with the study of the effect of machining parameters on material removal rate (MRR), Surface roughness (Ra), and Cutting force (Fc) while milling on hybrid MWCNT/Glass fiber reinforced polymer (GFRP) nanocomposite materials. Hybrid module using the multiple criteria optimizations by GRA and GRA-PCA method in Glass Fiber Reinforced Polymer (GFRP) doped with Multiwalled Carbon Nanotubes (MWCNT) to perform machining operation by carbon carbide tool. Taguchi based L9 orthogonal array was used as an experimental design. The GRA and GRA-PCA optimization modules effectively aggregated the machining output viz MRR, Ra & Fc into a single objective feature finally optimized by the Taguchi principle. The orthogonal setting and experimental setting are compared in the following preferred solution value GRA-Taguchi and GRA-PCA Taguchi. Whereby the percentage improvement of GRA-Taguchi and GRA-PCA Taguchi experimental data is 4.935 percent.

Optimization of machining parameters by Taguchi approach for machining of aluminium based metal matrix composite by abrasive water jet machining process

Aluminium based metal matrix composite plays a vital role in reducing weight and increase the efficiency of the products or parts. In this research, aluminium, nickel and magnesium are alloys for matrix silicon carbide and barium nitrate are reinforcement for developing the aluminium based metal matrix composites using the process of stir casting. The machinability of prepared composite is checked by abrasive water jet machining (AWJM) process. The three different input parameters are selected and that are water pressure, abrasive flow rate and traverse speed. Three levels for water pressure are 1800, 2400, 3000 bar, 150, 200,250 gm/min are abrasive flow rate and 50, 100, 150 mm/min are traverse speed. Taguchi technique is employed to choose the combination of machining parameters and examine the effect of machining parameters on material removal rate (MRR) and surface roughness (SR). The result shows that The ANOVA analysis on removal rate of material is confirms that selected machining parameters combine effect and the provide regression equation provides 96% of prediction for predicting the removal rate of material by considering the selected machining parameters. The traverse speed is more influential parameter on MRR and water pressure is most influential parameter on SR.

Experimental and Statistical Investigation of Machinability of AISI D2 Steel Using Electroerosion Machining Method in Different Machining Parameters

This study investigated the effects of machining parameters on the experimental and statistical results using the electric discharge method in the machining of AISI D2 cold work tool steel. The design of the experiment was established using the Taguchi L18 method. The effect of the experiment parameters on the performance characteristics was analyzed by analysis of variance (ANOVA). As a result of the study, it was determined that increasing amperage and pulse time affected the surface roughness and hole diameter on the surface of the material. The lowest values for surface roughness, machining time, hole diameter, and crater diameter were determined as 2.085 μm, 47 minutes, 12.010 mm, and 81.007 μm, respectively. The highest wear amount was obtained as 0.604 grams with the processed parameters in the ninth experiment. When the signal‐to‐noise ratios were examined, the optimum combinations of the control factors for surface roughness, hole diameter, crater diameter, wear amount, wear rate, and processing time were determined as A1B1C3, A1B1C3, A1B1C3, A1B3C1, A2B1C1, and A1B3C3, respectively. According to the ANOVA results, the most important parameters affecting the test results for surface roughness, hole diameter, crater diameter, wear amount, material wear loss, and processing time were determined as amperage (49.34%), time‐on (59.38%), amperage (55.65%), time‐on (56.92%), amperage (51.42%), and amperage (78.02%), respectively. When the gray relational degree was calculated for the maximum and minimum values, the ideal factors for all output results were found to be the parameters applied in the third experiment.

Optimization of WEDM parameters on surface integrity characteristics of NiTi shape memory alloy

The extensively adopted non-traditional approach of wire electrical discharge machining (WEDM) process can be formulated the complicated shapes and difficult-to-cut products with cost effective solution. The surface integrities and mechanical characteristics are sternly affected in the nickel titanium shape memory alloy (NiTi SMA) during WEDM process. In this study, an attempt has been made to investigate the effects of machining parameters on the surface integrity characteristics of NiTi SMA. The machining parameters such as servo voltage, input power, wire speed, pulse-on and pulse-off time were considered as inputs and their effects on surface integrity characteristics such as surface roughness, material removal rate, microstructure and hardness were studied. The machining process has been carried out with three levels of input parameters in the full factorial design. The TOPSIS analysis was used to evaluate the optimum machining parameters in order to exhibit the better surface integrity characteristics for NiTi alloy. The results of the optimization technique revealed that the better surface integrity properties (minimizing the roughness and maximizing the material removal rate) were achieved with the combination of 3 A input power, 9 µs pulse on time, 8 µs pulse off time, 20 V servo voltage and 3 m/min wire speed.

Analysis of Surface Roughness and Flank Wear Using the Taguchi Method in Milling of NiTi Shape Memory Alloy with Uncoated Tools

The aim of this study was to optimize machining parameters to obtain the smallest average surface roughness (Ra) and flank wear (Vb) values as a result of the surface milling of a nickel-titanium (NiTi) shape memory alloy (SMA) with uncoated cutting tools with different nose radius (rε) under dry cutting conditions. Tungsten carbide cutting tools with different rε (0.4 mm and 0.8 mm) were used in milling operations. The milling process was performed as lateral/surface cutting at three different cutting speeds (Vc) (20, 35 and 50 m/min), feed rates (fz) (0.03, 0.07 and 0.14 mm/tooth) and a constant axial cutting depth (0.7 mm). The effects of machining parameters in milling experiments were investigated based on the Taguchi L18 (21 × 32) orthogonal sequence, and the data obtained were analyzed using the Minitab 17 software. To determine the effects of processing parameters on Ra and Vb, analysis of variance (ANOVA) was used. The analysis results reveal that the dominant factor affecting the Ra is the cutting tool rε, while the main factor affecting Vb is the fz. Since the predicted values and measured values are very close to each other, it can be said that optimization is correct according to the validation test results.

Experimental Investigation on CO2 Laser-Assisted Micro-Grinding Characteristics of Al2O3

Fabricating micro-scale features in ceramic materials, such as alumina (Al2O3), is challenging because of their high hardness and brittleness. Laser-assisted machining, in which a laser beam is a heat source for pre-softening the local area on a workpiece, is an effective hybrid method for machining ceramics. The study identified the effects of carbon dioxide (CO2) laser-assisted micro-grinding (LAMG) with a wire electrical discharge grinding polycrystalline diamond tool on Al2O3. Comprehensive investigations have been conducted on the effects of laser beam machining itself and the effect of machining parameters, such as laser beam power, axial depth of cut, and feed rate. The average grinding force was found to decrease by 46% in the thrust direction and 44% in the feed direction, and surface roughness decreased by 17% with LAMG. Moreover, machining at a higher feed rate was possible without tool fracture. The results indicate that the CO2 laser heating of Al2O3 has significant advantages over conventional methods regarding machinability and channel geometry. Finally, an improved LAMG process to prevent edge cracks by revising the machining conditions is proposed.

Optimization of CNC machining process parameters for AA2014/WC composite

In this developed environment, most of the machineries and automobile parts are manufactured by using CNC machines. The working process for these requirements is common facing, turning, milling and so on. Of these surface roughness plays an important role. Since the strength and stability of the materials depends on the operation in which it undergoes on. The Taguchi method is adopted to reduce work effort. This method replaces the work of turning to minimize the surface roughness (SR). The goal of this analysis is to optimize the effects of machining parameters of CNC turning machine for the Aluminium Alloy AA2014+12%WC with response of SR through using Taguchi approach.

Analysis and comparison of laser cutting performance of solar float glass with different scanning modes

Cutting quality and efficiency have always been important indicators of glass laser cutting. Laser scanning modes have two kinds, namely, the spiral and concentric circle scanning modes. These modes can achieve high-performance hole cutting of thick solar float glass using a 532-nm nanosecond laser. The mechanism of the glass laser cutting under these two different scanning modes has been described. Several experiments are conducted to explore the effect of machining parameters on cutting efficiency and quality under these two scanning modes. Results indicate that compared with the spiral scanning mode, the minimum area of edge chipping (218340 µm2) and the minimum Ra (3.01 µm) in the concentric circle scanning mode are reduced by 9.4% and 16.4% respectively. Moreover, the best cutting efficiency scanning mode is 14.2% faster than that in the spiral scanning mode. The best parameter combination for the concentric circle scanning mode is as follows: Scanning speed: 2200 mm/s, number of inner circles: 6, and circle spacing: 0.05 mm. This parameter combination reduces the chipping area and sidewall surface roughness by 8.8% and 9.6% respectively at the same cutting efficiency compared with the best spiral processing parameters. The range of glass processing that can be achieved in the concentric circle scanning mode is wider than that in the spiral counterpart. The analyses of surface topography, white spots, microstructures, and sidewall surface element composition are also performed. The study concluded that the concentric circle scanning mode shows evident advantages in the performance of solar float glass hole cutting.

An Experimental Investigation of Surface Characterization for Zirconia Ceramic Using Electrochemical Discharge Machining Process

The industrial acceptance of ceramic materials is gradually increasing because of their attractive properties such as high strength, hot hardness, biocompatibility, insulating, and chemical stability over monolithic materials. The Zirconia (ZrO2) is a ceramic material of nonconductive and brittle in nature; thereby, it is very difficult to machine by very popular well-known machining methods like ECM, WEDM, EDM, etc. The machining problem resists its industrial applications. To overcome this problem, electrochemical discharge machining (ECDM) is a combination of electrochemical and electrical discharge machining methods used to machine the nonconductive ZrO2 material. The effects of machining parameters on machining responses were analysed through different graphs. Taguchi method-based L16 (45) orthogonal array was employed and utilized the acquired results to optimize the machining parameters. The experimental results reveal that the DC supply voltage and electrolyte concentration are the main governing factors in controlling the machining performance. The better material removal rate was identified at 65 V, 16 g/l electrolyte concentration, and 60-mm inter-electrode gap. FESEM images identified some of the micro-cracks on the machined hole surface when machining operations were carried out at a higher level of parameter setting. The presence of iron (Fe) was identified from EDS analysis, and it may be due to the diffused part of the steel cathode adhering to the machined surface.

Analytical model and experimental verification of Poisson burr formation in ductile metal machining

Previous investigations on the theoretical model to predict burr dimensions have normally been confined to a single geometric model, and the findings that have been proposed rarely take into account the influence of multi-physics factors on burr formation in the complex machining process. This paper proposes an analytical model to reveal subsurface plastic deformation behavior in machining of ductile material. This model is developed based on coupled thermo-mechanical factors. More importantly, the material property and tool edge arc are taken into consideration. According to the proposed model, the two approaches are presented to predict Poisson burr height and root thickness. Moreover, the material flow and burr formation mechanism are further investigated at great length. The effects of machining parameters and material properties on burr formation are analyzed and discussed in terms of plastic deformation behavior. The results show that this proposed model can describe burr morphology and predict burr size accurately. Poisson burr generation has a great sensitivity to machining parameters, as well as material property, and the transition of burr morphology is caused by severe lateral material flow owing to material softening effect at high temperature. There is the synchronous interaction between machining parameters and material property influencing burr formation. As a result, this study provides a valuable theoretical reference and basis for the deburring energy minimization, high surface quality, and machining parameters optimization.

Achieving machining effectiveness for AISI 1015 structural steel through coated inserts and grey-fuzzy coupled Taguchi optimization approach

Multi-objective optimization technique has become an essential step in the selection of cutting parameters. The intension of this research study is to analyze the performance characteristics of coated carbide inserts on their measured output responses during machining AISI 1015 steel. This paper targets to optimize the machining parameters such as speed, cutting depth, feed rate, cutting fluid flow rate, and coating material when multiple responses like surface roughness and flank wear were considered at the same time during turning. This research study also intends to examine scientifically the effect of machining parameters on quality measures during machining structural AISI 1015 steel. Cathodic arc evaporation–coated titanium aluminum nitride (TiAlN), titanium aluminum nitride/tungsten carbide-carbon (TiAlN/WC-C), and uncoated CNC inserts were used for the study. SEM and energy-dispersive X-ray analysis were performed to confirm the presence of coated elements. Micro-hardness was measured for coated, pure inserts, and TiAlN/WC-C-coated tool exhibited a higher hardness of 22.11 GPa compared with pure and coated tools. Five process parameters were used for this study, each at three stages. The experimental design was laid based on Taguchi’s L27 orthogonal array. In this research study, a multi-objective hybrid optimization technique comprising grey relation and fuzzy logic conjugated with the Taguchi design of experiments was used. The process parameters were optimized by grey relation analysis followed by fuzzification using Mamdani fuzzy engine and then optimized through Taguchi analysis. The parameter combination of speed 500 rpm, depth of cut of 1 mm, a feed rate of 0.05 mm/rev, cutting fluid flow rate at high level, and TiAlN/WC-C coating was found to be the optimum input parameters. The confirmatory test was also performed to validate the hybrid optimization approach.

Experimental Investigation on Recast Layer and Surface Roughness on Aluminum 6061 Alloy During Magnetic Field Assisted Powder Mixed Electrical Discharge Machining

Surface integrity aspects have been recognized as key research areas for manufacturing industries for determining the quality, longevity and reliability of machined engineering components. Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) is technological advancement in EDM process where the performance and stability of process increases by adding the suitable conductive powder in dielectric and using magnetic field. Aluminum 6061 alloy as workpiece was selected due to growing use in aviation, automotive, naval industries. In the present work, the study was conducted on EDM machined aluminum 6061 alloy with aluminum powder added in EDM oil and using magnetic field to analyze the effect of machining parameters on surface roughness, recast layer thickness and surface morphology. The input machining parameters, namely peak current, pulse on duration, pulse off duration, magnetic field and concentration of powder have been varied during the MFAPM-EDM process. Box–Behnken design approach of response surface methodology (RSM) was employed for experimental design to carry out the experiments. Quadratic model for predicting the surface roughness and recast layer thickness was developed using analysis of variance and regression analysis. Improvement in surface roughness and recast layer thickness were observed on machining with MFAPM-EDM process. Surface roughness and recast layer thickness were mostly influence by peak current and pulse on duration followed by concentration of powder and magnetic field. The surface morphology witness lesser cracks, voids, crater and molten debris particles present on the surface of machined aluminum 6061 alloy.

Effect of Cutting Parameters on Machinability of Hardened AISI 52100 Bearing Steel

In this study, the effects of machining parameters, namely feed rate, cutting speed and depth of cut on the surface roughness was investigated experimentally in hard turning of AISI 52100 bearing steel using cubic boron nitride insert under dry cutting condition. Taguchi method was utilized to reduce the number of trials to 9 for saving the time and manufacturing cost. The significant factor on the surface roughness was determined using analysis of variance. Furthermore, the optimum cutting parameter for reducing the surface roughness was obtained. The findings showed that the feed rate has the highest impact on surface roughness among any other cutting parameters, with 88.32% contribution.

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

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

Effect of process parameters on centre lathe of EN8 steel in turning process

Good surface finish and better material removal rate are desired for the proper functioning of produced parts. It was seen that the desired surface roughness and material removal rate were not obtained consistently in turning of EN 8 steel applications. These higher values of surface roughness results in rework and increasing cost, hence the main objective is optimization of surface roughness and material removal rate. A general optimization of surface roughness and material removal rate are necessary for the most of manufacturing industry. The surface quality and material removal rate are influenced by cutting speed, feed rate and depth of cut and many other parameters. In this experimental work optimum process parameters and the effect of machining parameters like spindle speed, feed and depth of cut on material removal rate and surface roughness are investigated. An L9 orthogonal array (mixed level design), analysis of variance (ANOVA) and the signal to noise (S/N) ratio are used in this study. Mixed levels of machining parameters are used and experiments are done on conventional lathe machine. EN8 steel material is used for manufacturing of shafts, studs, keys, general purpose axles etc. The most significant parameters for material removal rate are depth of cut, speed and least significant factor for MRR is Feed. For surface roughness speed, depth of cut are the most significant parameters and least significant factor is feed rate.

Surface roughness modeling using response surface methodology and a variant of multiquadric radial basis function

There are several methods for modeling surface roughness in computerized numerical control (CNC) milling process. This work proposes for the first time the use of response surface methodology (RSM) and a variant of the multiquadric radial basis function (MRBF) for the modeling of surface roughness (Ra) of graphite generated by means of the CNC milling process. In this variant, a norm with coefficients (weights) denoting the weighting of the effects of machining parameters is used. The machining parameters that have been most reported in literature were considered, which are cutting speed (S), feed rate (F), and cutting depth (D). Three mathematical models were developed to adjust the values of surface roughness: one model was obtained using RSM and two others were generated with the variant of MRBF. Values were assigned to effects of the weighted norm reducing it to the Euclidean norm, named Euclidean norm model (ENM). For the weighted norm model (WNM), values of effects of the machining parameters calculated by means of a factorial design were considered. Finally, in each model, the mean absolute percentage error (MAPE) was calculated: the lowest value and highest value of MAPE were obtained with response surface methodology model (RSMM) and ENM, respectively. However, lowest surface roughness was estimated and generated experimentally in graphite specimens with the machining parameter values obtained by means of WNM.

Comparative Study on the Performance of ZTA Cutting Tool with the Addition of Different Particle Size of MgO Additive

This paper investigated the performance of ZTA cutting tool with the addition of different particle size of MgO additive. Therefore, the objective of this research is to compare the effects of machining parameters on tool wears of ZTA cutting tools added with micro and nanoparticle of MgO. The experiments were conducted using BridgePort-Romi Powerpath CNC machine using a tool holder Sandvik Coromant (CoroTurn CCLNR 164D-4) to hold the cutting tools properly. The parameters are set up as cutting speeds used between range 354 to 472 m/min, feed rate from 0.1 to 0.5 mm/rev with a constant depth of cut of 0.2 mm. Three types of wear were analyzed which are flank wear, crater wear and tool chipping. Flank wear and crater wear images captured using measuring microscope (NIKON MM-400/L) and the crater wear areas are analyzed using MatLab programming software. Tool chipping is observed via SEM (JEOL JSM-5600). The experimental result shows that flank wear and crater wear increase when cutting speed and feed rate increase. ZMN cutting tool shows lower value of flank wear at 0.143 mm and 3.741 mm2 for crater wear than ZMM, 0.321 mm and 3.808 mm2 respectively. On the contrary, cutting speed did not affect the tool chipping severely as feed rate. Moreover, ZMN also shows that the tool breakage occurred severely than ZMM due to the high load on the tool nose.

Effects of machining parameters on surface quality of composites reinforced with natural fibers

ABSTRACT To minimize the surface roughness and delamination problems during the end milling of natural fiber reinforced composites (NFRCs), it is essential to understand the effects of the machining parameters (spindle speed and feed rate) and the kinematics of material removal. In this study, the effects of machining parameters on the machined surface quality – surface roughness (Ra) and delamination factor (Fd), during end milling of kenaf, jute and rice husk (RH) reinforced polypropylene (PP) composites has been analyzed using a two-factor, three-level experimental plan. It has been noticed that there are significant differences in the silicon contents (kenaf: 0.57%, jute: 4.16% and RH: 22.2%) and hardness values (kenaf: 0.15, jute: 0.20 and RH:0.59 GPa) of the three natural fibers, which has influenced the resulted surface quality of the machined NFRCs. Kenaf/PP composites showed the lowest delamination damages and the best surface finish most likely due to the fiber composition and morphology of kenaf, while predictably, RH/PP composites were the most demanding to machine. With a statistical analysis on the results, it is concluded that the machined surface quality is more influenced by spindle speed with percentage contribution showing at least three times more than feed rate for machining NFRCs.

Surface roughness and material removal rate analyses of hard copper alloy in wire electrical discharge machining

This experimental and statistical study focuses on investigation of the effects of machining parameters on surface roughness (SR) and material removal rate (MRR) in wire electrical discharge machining (WEDM) of hard copper (Cu) alloy. Experimental design was carried out using the L18 (21 × 32) orthogonal array according to the Taguchi method. The process parameters considered were wire type, pulse time and duration between two pulses. Copper-coated wire and zinc (Zn)-coated wires were used as cutting tools. Analysis of the signal-to-noise (S/N) ratio was utilized to investigate the effects of process parameters on the responses. Analysis of variance was employed to determine the percent contributions and significance levels of process parameters on responses. Analysis of the surface integrity and characteristics of the machined specimens was observed using scanning electron microscopy, and energy-dispersive X-ray spectroscopy analysis was employed. This study may be used as a reference to investigate SR and MRR in WEDM of hard copper alloy.

Multiphysics research on electrochemical machining of micro holes with internal features

Micro electrochemical machining (ECM) is practicable for machining micro holes with internal features by adjusting machining parameters along with machining depths. However, it is difficult to maintain the shape accuracy due to dramatically varied electrolyte temperature (T) and gas void fraction (vol) caused by the parameter variations. Taking the reverse tapered hole as an example, this research presents a multiphysics model to investigate the effects of machining parameters on T and vol and further optimize parameters for shape accuracy improvement. Firstly, the rules of current efficiency with various pulse-on times are measured from dissolution experiments. The gas fluxes are calculated from the Faraday current, and then multiphysics models coupling electric field, electrolyte flow, gas transport, and heat transfer are established by COMSOL software. The effects of the machining voltage, pulse-on time, duty ratio, and inlet pressure are investigated. Simulation results indicate that T and vol increase with the machining voltage or duty ratio and decrease with the inlet pressure. By using a smaller duty ratio or a higher inlet pressure, the sidewall dissolution region expands in a larger range. Increasing the inlet pressure is beneficial for reducing the negative influence of rising T and vol. However, excessive inlet pressure causes undesired material dissolution. The optimal inlet pressures are obtained from simulation results of the electrolyte vortex area. Micro ECM experiments are carried out to verify the simulation results and optimize the parameters. Micro reverse tapered holes with sidewall straightness of 8.6 μm are machined, and the shape accuracy is significantly improved.