Experimental Investigation Of Surface Roughness Research Articles

Experimental investigation of surface roughness of CT3 steel on adhesion strength of ARC spray Al -Mg alloy coating

Thermal spray-applied AlMg alloy coatings are frequently utilized in a variety of technical applications because of great corrosion resistance, and environmental friendliness. In this work, the effect of abrasive spraying parameters on the surface roughness of CT3 steel specimens as well as the effect of the surface roughness on the adhesion strength of Al-Mg alloy spray coating were experimentally investigated. The surface roughness was assessed using a portable roughness gauge. The adhesion strength of the coating was evaluated by the pull-off test, according to the JIS H8664-1977 standard. The experimental findings indicate that air pressure and spraying distance have great impacts on the surface roughness of CT3 steel. The adhesion strength of the Al-Mg coating applied on CT3 steel is found to be almost linearly proportional to the surface roughness. The maximum adhesion strength of 14 MPa was achieved at the highest Rz of about 61 µm.

Experimental Investigation of Surface Roughness and MRR in Rotary-Ultrasonic Machining of Float Glass

Experimental Investigation of Surface Roughness and MRR in Rotary-Ultrasonic Machining of Float Glass

Experimental Investigation of Surface Roughness and Material Removal Rate in Wire EDM of Stainless Steel 304.

Its unexcelled mechanical and physical properties, in addition to its biocompatibility, have made stainless steel 304 a prime candidate for a wide range of applications. Among different manufacturing techniques, electrical discharge machining (EDM) has shown high potential in processing stainless steel 304 in a controllable manner. This paper reports the results of an experimental investigation into the effect of the process parameters on the obtainable surface roughness and material removal rate of stainless steel 304, when slotted using wire EDM. A full factorial design of the experiment was followed when conducting experimental trials in which the effects of the different levels of the five process parameters; applied voltage, traverse feed, pulse-on time, pulse-off time, and current intensity were investigated. The geometry of the cut slots was characterized using the MATLAB image processing toolbox to detect the edge and precise width of the cut slot along its entire length to determine the material removal rate. In addition, the surface roughness of the side walls of the slots were characterized, and the roughness average was evaluated for the range of the process parameters being examined. The effect of the five process parameters on both responses were studied, and the results revealed that the material removal rate is significantly influenced by feed (p-value = 9.72 × 10-29), followed by current tension (p-value = 6.02 × 10-7), and voltage (p-value = 3.77 × 10-5), while the most significant parameters affecting the surface roughness are current tension (p-value = 1.89 × 10-7), followed by pulse-on time (1.602 × 10-5), and pulse-off time (0.0204). The developed regression models and associated prediction plots offer a reliable tool to predict the effect of the process parameters, and thus enable the optimizing of their effects on both responses; surface roughness and material removal rate. The results also reveal the trade-off between the effect of significant process parameters on the material removal rate and surface roughness. This points out the need for a robust multi-objective optimization technique to identify the process window for obtaining high quality surfaces while keeping the material removal rate as high as possible.

An experimental investigation of surface roughness in 3D-printed PLA items using design of experiments

This work investigates the effect of 3D-printing parameters on surface roughness in polylactic acid printed material by adopting Taguchi's design of experiments approach. The control parameters under study were: number of shells, printing temperature, infill rate, and printing pattern. As the response, mean surface roughness (Ra) was selected. The control parameters were assigned to an L9 orthogonal array to organize the experiments and obtain the mean surface roughness results. It is concluded that printing temperature is the dominant parameter that affects surface roughness when it comes to 3D printing of polylactic acid material followed by printing pattern, infill rate, and the number of shells.

Experimental Investigation of Surface Roughness in Milling of DuralcanTM Composite.

In today’s developing aircraft and automotive industry, extremely durable and wear-resistant materials, especially in high temperatures, are applied. Due to this practical approach, conventional materials have been superseded by composite materials. In recent years, the application of metal matrix composites has become evident in industry 4.0. A study has been performed to analyze the surface roughness of aluminum matrix composites named Duralcan® during end milling. Two roughness surface parameters have been selected: arithmetical mean roughness value Ra and mean roughness depth Rz regarding the variable cutting speed. Due to the classification of aluminum matrix composites as hard-to-cut materials concerning excessive tool wear, this paper describes the possibility of surface roughness prediction using machine learning algorithms. In order to find the best algorithm, Classification and Regression Tree (CART) and pattern recognition models based on artificial neural networks (ANN) have been compared. By following the obtained models, the experiment shows the effectiveness of roughness prediction based on verification models. Based on experimental research, the authors obtained the coefficient R2 for the CART model 0.91 and the mean square error for the model ANN 0.11.

Experimental Investigation of Surface Roughness Using Uncoated and Coated Tungsten Carbide Cutting Tool in Turning Operation

The cutting process is an important process of industrialization. It is requisite to using advantage quality cutting tools in order to preserve the type of product. Coating on the cutting tool has a substantial effect in terms of mechanical properties and the end results of the product. The cutting tool can be manufactured in various material types, but today's cemented tungsten carbide is the most commonly used material in the tool industry because its properties comply with manufacturers' requirements. This study investigates the impact of an Al2O3 coated cutting tool relative to an uncoated cutting tool on the dry cutting process. Different parameters are used in the cutting process when cutting the metal. The cutting parameters used are feed rate and cutting speed, An analysis of the effects of these parameters on the surface roughness. In this analysis, the surface roughness are measured for components turned from steel1040, The L9 Taguchi orthogonal arrays and analyses of variance (ANOVA) was employed to analyze the influence of these parameters. In the case of (uncoated, Al2O3 coated tool), the better surface roughness (SR) with used feed rate (0.05 mm / rev) and cutting speed (140 m/min) where the roughness value was (0.81μm) and (0.78μm) Respectively. The results of this study indicate that the ideal parameters combination for the better surface finish was high cutting speed and low feed rate.

Experimental investigation of surface roughness and chip morphology during machining of austenitic stainless steel 303 with pvd coated (TiAlN) insert

Optimizing the influencing parameters of turning operation is a precious thing which determines the desired level of quality in Material Removal Rate (MRR) and Surface Roughness (SR). In this investigation, Taguchi based Grey Relational Analysis (GRA) has been used optimizing the effective process parameters such as depth of cut, feed rate and cutting speed on Stainless Steel 303 (SS 303) material while the specimen is turned with PVD (TiAlN) coated cutting tool. The experimental combinations have been planned based on Taguchi’s Design of Experiments technique. The optimal input parameter combination has been identified as 600 m min−1 spindle speed, 0.1 mm rev−1 feed rate and 0.2 mm depth of cut. The most influencing factor affecting the overall responses of turning process has been found out using Analysis of Variance approach as spindle speed (37.91%). Second-order mathematical models have been developed using Design Expert software for all the considered output responses, which provide the experimental values within the considered range of process parameters even without performing the actual experimentation. 3D surface plots have been generated and analyzed for interpreting the correlation between the process variables. SEM images taken on the machined surfaces and chips have been analyzed and presented in order to validate the optimization results.

Experimental investigation of surface roughness and cutting force during machining of SS43100 by using coated and uncoated carbide inserts

Machining processes are the accurate metal removal processes for shaping components in the manufacturing industry. The main challenges of the manufacturing industry are to increase productivity and quality. Manufacturing industries are trying to reduce the cost of machined parts which are manufactured by different machined methods. Machining hard metals is a challenging task. In the presented research work machining parameters were investigated for machining of SS43100 by using coated and uncoated carbide tool inserts. Carbide tool inserts were coated by Ti16Zr using the PVD method of coating. Experiments were performed during the turning operation of SS43100 by coated and uncoated tool inserts. Cutting speed range were 150r.p.m, 250 r.p.m., 350 r.p.m., feed were 0.085 mm/rev, 0.095 mm/rev, 0.1 mm/rev. and depth of cut was 0.1 mm, 0.15 mm, and 0.2 mm selected as controlling factors. Surface roughness and cutting force were selected as response factors. Digital lathe tool dynamometer was used for cutting force measurement and ITI surface tester RS232 was used for surface roughness measurement. In the experimental study and analysis of output response parameters, Taghuchi L9 orthogonal array model has used The results obtained were optimized using the Taghuchi technique for cutting forces and surface roughness. The Taghuchi technique was performed for combinations of each input variable in linear fit model multivariate analytics. Experimental results were compared and models established supported by evidence.

The Experimental Investigation of Surface Roughness After Dry Turning of Steel S235

Abstract Nowadays lot of scientific work inspired by industry companies was done with the aim to avoid the use of cutting fluids in machining operations. The reasons were ecological and human health problems caused by the cutting fluid. The most logical solution, which can be taken to eliminate all of the problems associated with the use of cooling lubricant, is dry machining. In most cases, however, a machining operation without lubricant finds acceptance only when it is possible to guarantee that the part quality and machining times achieved in wet machining are equalled or surpassed. Surface finish has become an important indicator of quality and precision in manufacturing processes and it is considered as one of the most important parameter in industry. Today the quality of surface finish is a significant requirement for many workpieces. Thus, the choice of optimized cutting parameters is very important for controlling the required surface quality. In the present study, the influence of different machining parameters on surface roughness has been analysed. Experiments were conducted for turning, as it is the most frequently used machining process in machine industry. All these parameters have been studied in terms of depth of cut (ap), feed rate (f) and cutting speed (vc). As workpiece, material steel S235 has been selected. This work presents results of research done during turning realised on conventional lathe CDS 6250 BX-1000 with severe parameters. These demonstrate the necessity of further, more detailed research on turning process results.

Experimental Investigation of Surface Roughness of Cutting Parameters in T6 Aluminum Alloy Milling Process

In this study, optimum machining conditions were determined by investigating the surface roughness of the 7075-T6 aluminum alloy milling, depending on the spindle speed (rpm), feed per tooth (Fz-mm/tooth) and the cooling type parameters. Taguchi experiment design method was used to save time and cost. Experiments were based on the Taguchi L16 orthogonal array and signal/noise (S/N) ratios were used in the evaluation of the test results. Optimum surface roughness values were determined with Taguchi optimization. In addition, variance analysis and regression analysis were performed. Confirmation tests were conducted to verify the work. As a result of the confirmation tests, it was found that the surface roughness optimization in the milling of the 7075-T6 aluminium alloy was successfully applied.

An Experimental Investigation of surface roughness of FDM Build parts by Chemical Misting

Rapid Prototyping or additive manufacturing is a process of creating 3 dimensional objects by adding materials layer by layer. It is a modern manufacturing process of producing more complex shaped materials which might be difficult or impossible in traditional machining processes. This technique has application in all fields of life and many tools artefacts circuit boards etc. have been produced by this process. It also produces new bones to be replaced by older ones. In this treatise an experiment has been conducted to determine the surface roughness before and after chemical treatment thereby comparing both values. Design of Experiments was conducted in Minitab by Taguchi analysis and six parameters, three-part building parameters Raster Angle, Raster Width, Air Gap, and three-part smoothing parameters Temperature, Time, Cycle have been found out. Analysis of Variance (ANOVA)has been carried out to determine the relationship of each parameter along with regression equation. Also surface plots have been drawn to examine the effect of parameters on surface roughness.

Experimental investigation of surface roughness and cutting ratio in a spraying cryogenic turning process

Surface roughness is one of the most common criteria indicating the surface finish of the part, which depends on various factors including cutting parameters, geometry of the tool, and cutting fluid. One of the goals of using cutting fluids in machining processes is to achieve improved surface finish. In addition to high costs, commonly used cutting fluids cause dermal and respiratory problems to the operators as well as environmental pollution. The present article aims at investigating the effect of spray cryogenic cooling via liquid nitrogen on surface roughness and cutting ratio in turning process of AISI 304 stainless steel. Through conducting experimental tests, the effects of cutting speed, feed rate, and depth of cut on surface roughness and cutting ratio have been compared in dry and cryogenic turning. A total number of 72 tests have been carried out. Results show that cryogenic turning of AISI 304 stainless steel reduces surface roughness 1%–27% (13% on the average), compared to dry turning. The obtained results showed that the cutting ratio in cryogenic turning is averagely increased by 32% in comparison with dry turning, also that chip breakage is improved in cryogenic turning.

Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert

BackgroundNow-a-days, newer hardened steel materials are coming rapidly into the market due to its wide applications in various fields of engineering. So the machinability investigation of these steel materials is one of the prime concern for practicing engineers, prior to actual machining.MethodsThe present study addresses surface roughness, flank wear and chip morphology during dry hard turning of AISI 4340 steel (49 HRC) using CVD (TiN/TiCN/Al2O3/TiN) multilayer coated carbide tool. Three factors (cutting speed, feed and depth of cut) and three-level factorial experiment designs with Taguchi’s L9 Orthogonal array (OA) and statistical analysis of variance (ANOVA) were performed to investigate the consequent effect of these cutting parameters on the tool and workpiece in terms of flank wear and surface roughness. For better understanding of the cutting process, surface topography of machined workpieces, wear mechanisms of worn coated carbide tool and chip morphology of generated chips were observed by scanning electron microscope (SEM). Consequently, multiple regression analysis was adopted to develop mathematical model for each response, along with various diagnostic tests were performed to check the validity and efficacy of the proposed model. Finally, to justify the economical feasibility of coated carbide tool in hard turning application, a cost analysis was performed based on Gilbert’s approach by evaluating the tool life under optimized cutting condition (suggested by response optimization technique).ResultsThe results shows that surface roughness and flank wear are statistically significant influenced by feed and cutting speed. In fact, increase in cutting speed resulted in better surface finish as well as increase in flank wear. Tool wear describes the gradual failure of cutting tool, caused grooves by abrasion due to rubbing effect of flank land with hard particles in the machined surface and high cutting temperature. Chip morphology confirms the formation of saw-tooth type of chip with severity of chip serration due to cyclic crack propagation caused by plastic deformation. The total machining cost per part is found to be $0.13 (i.e. in Indian rupees Rs. 8.21) for machining of hardened AISI 4340 steel with coated carbide tool.ConclusionsFrom the study, the effectiveness and potential of multilayer TiN/TiCN/Al2O3/TiN coated carbide tool for hard turning process during dry cutting condition possesses high yielding and cost-effective benefit to substitute the traditional cylindrical grinding operation. Apart, it also contributes reasonable option to costlier CBN and ceramic tools.

Experimental investigation of surface roughness in high-speed micro end milling of near alpha titanium alloy

Super alloys are widely used in many applications such as aerospace, automotive, biomedical, marine, mining and oil industries. In high-speed micro end milling (HSMEM) of super alloys, the proper selection of cutting tool is necessary to achieve good surface quality without burrs. Surface roughness characterisation is crucial on the work materials to achieve the desired production rate in limited time and at low cost. In this research work, surface roughness characterisation was investigated in order to opt for the better possible tool for machining Near Alpha Titanium Alloy Grade-12 under feasible conditions. The influence of machining parameters i.e. cutting speed, feed and depth of cut on surface roughness was investigated in the present work. Experiments were conducted under dry cutting conditions using Uncoated, PVD Coated TiAlN & AlTiN tungsten carbide tools. It was observed that machining with uncoated tungsten carbide tools generates less surface roughness on near alpha titanium alloy.

Experimental investigation of surface roughness in high-speed micro end milling of near alpha titanium alloy

Experimental investigation of surface roughness in high-speed micro end milling of near alpha titanium alloy

Experimental Investigation of Surface Roughness by Optimizing Process Parameter in Turning Operation of Aluminum Alloy

Experimental Investigation of Surface Roughness by Optimizing Process Parameter in Turning Operation of Aluminum Alloy

An experimental investigation of surface roughness in the drilling of MWCNT doped carbon/epoxy polymeric composite material

The objective of this research is to investigate the effect of multi-walled carbon nanotube (MWCNT) loading on the surface roughness of drilled hole, in the drilling of MWCNT doped carbon/epoxy polymeric composite material. Root mean square roughness (Rq) was used to assess the effect of MWCNT. Rq was measured at the both side i.e. entrance and exit of hole. Experiment was performed using Box- Behnken Design to develop an empirical model to predict the surface roughness value at the entrance and exit. The developed model was accurate within the level of confidence. Due to loading of MWCNT in polymer matrix, surface roughness of hole at entrance and exit are improved.

Experimental investigation of Surface roughness of cylinder liner for HT 100 material using RSM Technique

Experimental investigation of Surface roughness of cylinder liner for HT 100 material using RSM Technique

Experimental investigation of Surface Roughness and Cutting force in CNC Turning - A Review

The main purpose of this review paper is to check whether quality lies within desired tolerance level which can be accepted by the customers. So, experimental investigation surface roughness and cutting force using various CNC machining parameters including spindle speed (N), feed rate (f), and depth of cut (d),flow rate (Q) and insert nose radius (r). As such, a solemn attempt is made in this paper to investigate the response parameters, viz., Cutting force and Surface Roughness (Ra) a by experimentation on EN 19 turning process. The Design of experiments is carried-out considering Taguchi Technique with four input parameters, namely, spindle speed, feed rate, and depth of cut, flow rate and insert nose radius .The experiments are conducted considering the above materials for L16 and then the impact of each parameter is estimated by ANOAVA. Then the regression analysis is carried-out to find the trend of the response of each material. This experimental study aims at taguchi method has been applied for finding the effect on surface roughness and cutting force by various process parameters. And after that we can easily find out that which parameter will be more affect.

Experimental Investigation of Surface Roughness and Power Consumption in Turning Operation of EN 31 Alloy Steel

The paper presents an experimental study of power consumption and roughness characteristics of surface generated in turning operation of EN-31 alloy steel with TiN+Al2O3+TiCN coated tungsten carbide tool under different cutting parameters. The study sho ws the influences of three cutting parameters like spindle speed, depth of cut and feed rate affecting surface roughness as well as p ower consumption while turning operation of EN-31 alloy steel. The experimental setup includes five different spindle speed k eeping feed rate of 0.08 mm/rev and depth of cut of 0.4 mm constant, five different feed rate keeping spindle speed of 710 rpm and depth of cut of 0.4 mm constant and five different depth of cut keeping feed rate of 0.08 mm/rev and spindle speed of 710 rpm constant. The experiments were conducted to investigate the effectiveness of surface roughness and power consumption in tu rning operation of EN 31 alloy steel. © 2014 The Authors. Published by Elsevier Ltd. Selection and/or peer-review under responsibility of the Org anizing Committee of ICIAME 2014.