Influence Of Different Machining Parameters Research Articles

Study on sinusoidal lapping micro-structured surface by abrasive stone with staggered abrasive particles

In order to manufacture structured surfaces, firstly, the abrasive stone model with staggered abrasive particles is established with mathematical methods. Secondly, the motion of abrasive particles on the abrasive stone is designed. Finally, the surface morphology of the workpiece is simulated. The simulated workpiece morphology under different machining parameters is compared, and the influence of different machining parameters on the workpiece surface morphology is obtained. The results indicate that the microstructured surface can be lapped by using the abrasive stone of staggered abrasive particles. As the amplitude and frequency of the abrasive stone increase, the number of protrusions increases, and the area of individual protrusions decreases.

Tensile Test Optimization Using the Design of Experiment and Soft Computing

The tensile testing of various materials to evaluate the influence of different machining parameters is a fundamental requirement in every industry. The objective of this study is to investigate the effects of temperature, the area of the contact point, and the operator on the tensile test of brass samples. This study employs a hybrid soft computing approach, integrating an adaptive network-based fuzzy inference system (ANFIS), genetic algorithm (GA) optimization, and design of experiments (DOE). By combining these techniques, the study aims to leverage their individual strengths and achieve superior results. The results reveal that the area of the contact point exerts the most significant influence on the tensile test, followed by the operator and temperature. The optimal levels of these parameters are determined to be a level of two for the operator, a level of three for the area of the contact point, and a level of one for the temperature. The study demonstrated that the hybrid soft computing method outperformed the traditional DOE method, achieving a substantial improvement in elongation of 32.9%. The optimized combination of machining parameters led to a notable enhancement in the brass samples’ tensile properties, highlighting the effectiveness of the applied methodology. The marginal error of only 0.72% in the hybrid approach showcases its high precision and reliability in determining the optimal levels of machining parameters. These findings underscore the potential of the Taguchi optimization method, ANFIS, and GA in achieving superior results in the tensile testing of materials, particularly in cases where multiple parameters are involved. The research results provide valuable insights for industries relying on precise material characterization, offering a robust methodology for optimizing tensile testing procedures. The study’s success in leveraging a hybrid soft computing approach serves as a promising avenue for future research in the field of material testing and optimization techniques.

Research on the influence of different machining parameters and cooling and lubrication methods on the change of chip color on tool life

Cutting fluid has always been a commonly used cooling and lubrication method in machining. However, the traditional flood cooling method is not environmentally friendly, and the purchase of cutting fluid and disposal of waste fluid also create a lot of costs for employers. The emergence of MQL and air cooling can provide Due to the advantages of environmental protection and cost, this study uses three cutting conditions, dry, cold air gun and MQL, and two high and low cutting speeds to conduct experiments to record tool wear and analyze chip chromaticity. The results show that the two cooling methods are better than dry cutting. It can improve the tool life by about 40%, and with the increase of tool wear, the chip chromaticity also has a clear trend of change. The chip chromaticity data is predicted by the back-transmission neural network (BPNN), and the average absolute error percentage of the model is 11.12%. According to the prediction ability of the mean absolute percentage error (MAPE), this model has good prediction ability, and the relevant color and tool wear data will help to establish a tool wear prediction model for related materials and cooling methods in the future.

Effect of temperature on milling stability of thin-walled parts

Milling, as a common machining method, is widely used in rough machining and final finishing of various materials. In this paper, according to the milling temperature produced in the milling process, the formula of heat distribution coefficient for workpiece milling is established. By means of Deform-3D finite element software to carry out orthogonal cutting simulation of workpiece, the influence of different machining parameters on milling heat distribution coefficient is studied, the optimal machining parameters are determined, and the milling temperature experiment is carried out to verify the simulation temperature. The experimental results show that the simulation temperature is very close to the experimental workpiece temperature, and the error is very small, which verifies the accuracy of the method. At the same time, the influence of different initial temperature of workpiece on the milling force and stability is also studied. The results show that proper heating of the workpiece can effectively improve the milling stability of the thin-walled parts.

Influence of Additive Manufactured Stainless Steel Tool Electrode on Machinability of Beta Titanium Alloy

Additive manufacturing technology provides a gateway to completely new horizons for producing a wide range of components, such as manufacturing, medicine, aerospace, automotive, and space explorations, especially in non-conventional manufacturing processes. The present study analyzes the influence of the additive manufactured tool in electrochemical micromachining (ECMM) on machining beta titanium alloy. The influence of different machining parameters, such as applied voltage, electrolytic concentration, and duty ratio on material removal rate (MRR), overcut, and circularity was also analyzed. It was inferred that the additive manufactured tool can produce better circularity and overcut than a bare tool due to its higher corrosion resistance and localization effect. The additive manufactured tool can remove more material owing to its strong atomic bond of metals and higher electrical conductivity.

Elbow precision machining technology by abrasive flow based on direct Monte Carlo method

The investigation was carried out on the technical problems of finishing the inner surface of elbow parts and the action mechanism of particles in elbow precision machining by abrasive flow. This work was analyzed and researched by combining theory, numerical and experimental methods. The direct simulation Monte Carlo (DSMC) method and the finite element analysis method were combined to reveal the random collision of particles during the precision machining of abrasive flow. Under different inlet velocity, volume fraction and abrasive particle size, the dynamic pressure and turbulence flow energy of abrasive flow in elbow were analyzed, and the machining mechanism of particles on the wall and the influence of different machining parameters on the precision machining quality of abrasive flow were obtained. The test results show the order of the influence of different parameters on the quality of abrasive flow precision machining and establish the optimal process parameters. The results of the surface morphology before and after the precision machining of the inner surface of the elbow are discussed, and the surface roughness Ra value is reduced from 1.125 µm to 0.295 µm after the precision machining of the abrasive flow. The application of DSMC method provides special insights for the development of abrasive flow technology.

Experimental Study on Tool Wear and Delamination in Milling CFRPs with TiAlN- and TiN-Coated Tools

Carbon fiber-reinforced polymers (CFRPs) have very good mechanical properties, such as extremely high tensile strength/weight ratios, tensile modulus/weight ratios, and high strengths. CFRP composites need to be machined with a suitable cutting tool; otherwise, the machining quality may be reduced, and failures often occur. However, as a result of the high hardness and low thermal conductivity of CFRPs, the cutting tools used in the milling process of these materials complete their lifetime in a short cycle, due to especially abrasive wear and related failure mechanisms. As a result of tool wear, some problems, such as delamination, fiber breakage, uncut fiber and thermal damage, emerge in CFRP composite under working conditions. As one of the main failure mechanisms emerging in the milling of CFRPs, delamination is primarily affected by the cutting tool material and geometry, machining parameters, and the dynamic loads arising during the machining process. Dynamic loads can lead to the breakage and/or wear of cutting tools in the milling of difficult-to-machine CFRPs. The present research was carried out to understand the influence of different machining parameters on tool abrasion, and the work piece damage mechanisms during CFRP milling are experimentally investigated. For this purpose, cutting tests were carried out using a (Physical Vapor Deposition) PVD-coated single layer TiAlN and TiN carbide tool, and the abrasion behavior of the coated tool was investigated under dry machining. To understand the wear process, scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS) was used. As a result of the experiments, it was determined that the hard and abrasive structure of the carbon fibers caused flank wear on TiAlN- and TiN-coated cutting tools. The best machining parameters in terms of the delamination damage of the CFRP composite were obtained at high cutting speeds and low feed rates. It was found that the higher wear values were observed at the TiAlN-coated tool, at the feed rate of 0.05 mm/tooth.

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.

COMPLEXITY-BASED ANALYSIS OF THE INFLUENCE OF TOOL GEOMETRY ON CUTTING FORCES IN ROUGH END MILLING

It is known that geometry of cutting tool affects the cutting forces in machining operations. In addition, the value of cutting forces changes during machining operations and creates a chaotic time series (signal). In this paper, we analyze the variations of the complex structure of cutting force signal in rough end milling operation using fractal theory. In fact, we analyze the variations of cutting force signal due to variations of tool geometry (square end mill versus serrated end mill). In case of each type of end mill, we did the machining operation in wet and dry conditions. Based on the results, the fractal structure of cutting force signal changes based on the type of milling tool. We also did the complexity analysis using approximate entropy to check the variations of the complexity of cutting force signal, where the similar behavior of variations between different conditions was obtained. The method of analysis that was used in this research can be applied to other machining operations to study the influence of different machining parameters on variations of fractal structure of cutting force.

Investigation of Tool Core Temperature and Mechanical Tool Load in Milling of Ti6Al4V

The special properties of titanium and titanium alloys, such as their high strength-to-weight ratio, their corrosion resistance, and their biocompatibility are of high importance for aerospace, medical and other industrial applications. However, components made of these difficult-to-cut materials entail major challenges for machining processes. High thermo-mechanical tool load results in rapid tool wear, and the already significant machining costs are further increased by premature tool exchange to avoid tool breakage, damaging the valuable workpieces. Both, tool wear progress and risk of tool breakage can be reduced by gaining extensive knowledge about the thermo-mechanical tool load over the tool life time. In this paper, the influence of different machining parameters on the end milling tools’ core temperature and the resulting active force affecting the tool are investigated over tool life time. To measure thermal and mechanical tool loads, an adapted sensory tool holder was used. The results show a strong interdependence between tool load, tool core temperature, machining parameters and tool wear.

Experimental and PFEM-simulations of residual stresses from turning tests of a cylindrical Ti-6Al-4V shaft

Alloy Ti-6Al-4V is a frequently used material in aero space applications due the high strength and low weight. This material is however often considered as a difficult to machine alloy due to several material properties such as the inherent characteristics of high hot hardness and strength which is causing an increased deformation of the cutting tool during machining. The thermal properties also cause a low thermal diffusion from locally high temperatures in the cutting zone that allows for reaction to the tool material resulting in increased tool wear.Predicting the behavior of machining of this alloy is therefore essential when selecting machining tools or machining strategies. If the surface integrity is predicted, the influence of different machining parameters could be studied using Particle Finite Element (PFEM)-simulations. In this investigation the influence from cutting speed and feed during turning on the residual stresses has been measured using x-ray diffraction and compared to PFEM-simulations.The results showed that cutting speed and feed have great impact on the residual stress state. The measured cutting force showed a strong correlation especially to the cutting feed. The microstructure, observed in SEM, showed highly deformed grains at the surface from the impact of the turning operation and the full width half maximum from the XDR measurements distinguish a clear impact from different cutting speed and feed which differed most for the higher feed rate.The experimental measurements of the residual stresses and the PFEM simulations did however not correlate. The surface stresses as well as the sign of the residuals stresses differed which might be due to the material model used and the assumption of using a Coulomb friction model that might not represent the cutting conditions in the investigated case.

Surface integrity in electrochemical machining processes: An analysis on material modifications occurring during electrochemical machining

In contrast to most other manufacturing technologies, in electrochemical machining processes only slight changes in material characteristics in the rim zone of workpieces are stated in the literature. Due to the physical active principle, no thermo-mechanically induced phase changes or the evolution of a so-called white layer were ever observed. Aside of this fact, a not inconsiderable number of smaller modifications in the rim zone were found in the past. The most common effects occurring during electrochemical machining are the generation of a passive layer on the surface by changing the local chemical composition of the material, the selective dissolution of one metallic phase, or the occurrence of flow marks. Consequently, the last two effects also change the surface roughness as the marks and dissolved phases represent ditches in the surface. Therefore, in this article, material modifications occurring during electrochemical machining are presented. Their influence on the surface integrity is exemplarily analyzed for the heat-treatable steel 42CrMo4. In addition, first steps for a correlation of material loadings that promote these changes, the so-called process signature, are made. Based on this, the influence of different machining parameters can be compared to set up rim zone properties purposefully.

Surface Roughness Analysis on the Dry Turning of an Al-Cu Alloy

Nowadays, surface finish has become an important indicator of quality and precision in manufacturing processes and it is considered one of the most important parameter in Industry. In this present study, the influence of different machining parameters on surface roughness has been analyzed. All these parameters have been studied in terms of depth of cut (ap), feed rate (F), cutting speed (Vc) and tool radius (R). A 2030-T4 aluminium alloy has been selected. Moreover, Design of Experiments (DOE) techniques have been used to predict the surface quality in advance and to select the optimal turning conditions. The experimental results revealed that for dry turning operations and for the amplitude parameters, the most significant factor was the interaction effect between the depth of cut and the feed rate. In addition, for facing operations, the feed rate turned out to be the most statistically influential factor of all the surface roughness parameters.

Optimization of machining parameters in turning using Design of Experiments (DOE) and Analysis of Variance (ANOVA)

Metal cutting process is one of the complex process which has numerous factors contributing towards the quality of the finished product. CNC turning is one among the metal cutting process in which quality of the finished product depends mainly upon the machining parameters such as feed, speed, depth of cut, type of coolant used, types of inserts used etc. Similarly the work piece material plays an important role in metal cutting process. While machining, optimized machining parameters results in good surface finish, low tool wear, etc. This study involves in identifying the optimized parameters in CNC turning. Based on the performance of test results of various sets of experiments performed for analyzing the influence of different machining parameters on the cutting force in the machining of mild steel using HSS cutting tool, Factorial 3k design of experiment (DOE), Analysis of variance (ANOVA), F-test values. The experimental results show that the cutting force and feed force are low at low feed and depth of cut and comparatively high at high feed and high depth of cut. The greater the feed and depth of cut , larger the cross sectional area of the uncut chip, the volume of the deformed metal and consequently the greater is the resistance of the material to chip formation and larger is the force Pz will be in turning operation