Mm Depth Of Cut Research Articles

Minimization of cutting force, temperature and surface roughness through GRA, TOPSIS and Taguchi techniques in end milling of Mg hybrid MMC

Present study investigates the effect of material and machining parameters on cutting force, surface roughness and temperature in end milling of Magnesium (Mg) Metal Matrix Composite (MMC) using carbide tool. Mg hybrid composite was fabricated by reinforcing Cathode Ray Tube (CRT) panel glass, an intensifying E-waste and Boron Nitride (BN) particles through powder metallurgy method. The milling experiments were conducted based on L27 orthogonal array designed by considering CRT glass particle size and weight percentage, tool diameter, speed, feed and depth of cut as input process parameters. Multi objective optimization was done through Grey Relational Analysis (GRA) and Techniques for Order Preferences by Similarity to Ideal Solution (TOPSIS). Both of the techniques provided a similar optimum parameter condition i.e. 10 µm particle size, 5% reinforcement, 8 mm diameter tool, 710 rpm speed, 20 mm/min feed and 0.5 mm depth of cut that outcomes in 139.48 N in-feed force, 63.92 N cross-feed force, 42.6 N thrust force, 68.96 °C temperature and 0.198 µm surface roughness. ANOVA is performed to identify significance and also the effect of each process variables on response parameters. Though all the parameters were found to be significant, reinforcement weight% and particle size affects the response parameters as that of machining parameters whereas speed turned to be the least significant factor.

Experimental Investigation of Tool Vibration Effect on the Surface Roughness in Facing Operation of PMMA Material

Poly Methyl Methacrylate (PMMA) is one of the few plastics used in optical applications. The Diamond Turning machine is used for cutting PMMA for optical applications, as finish cut and rough cut are performed using the CNC lathe machine. The optical applications require the best surface finish for the maximum transmission of light and to avoid light scattering. The best surface finish can be achieved by machining PMMA at optimized parameters. The optimum cutting parameters may not give good results due to the presence of vibration in the process. In this paper, the effect of vibration on cutting parameters is experimentally studied. The experimentation has been carried out to determine the relation between the tool vibration acceleration amplitude and the surface finish. The facing operation is performed on the PMMA material. The operation is performed using the CNC lathe machine. The three level full factorial design approach is used for the experimentation. The feed rate, cutting speed and the depth of cut are selected as influencing parameters by keeping all the other parameters constant. The Tungsten carbide cutting tool is used for the cutting operation. The accelerometer is used to gather vibration data by using the NI LABVIEW software. The analysis of the obtained results is done by using ANOVA. It is seen in the graphs that vibrations in Z- direction mainly affect the surface finish. The maximum value of the surface finish is 0.243µm, when acceleration is 2.93 m/s2, and the minimum value of surface finish 0.05µm, when acceleration is 2.03 m/s2. The optimum parameter values to obtain the minimum vibrations and the best surface finish are 274.89 m/min cutting speed, 0.05 mm/rev and 0.1 mm depth of cut.

Evaluation of performance of nanofluid using multiwalled carbon nanotubes for machining of Ti–6AL–4V

ABSTRACTMachining of titanium alloys generate very high temperature in the cutting zone. This results in rapid tool wear and poor surface properties. Therefore, improvement in cutting performance in machining of titanium alloys is very much dependent on effectiveness of the cooling strategies applied. In the present work, performance of nanofluid using multiwalled carbon nanotubes (MWCNTs) dispersed in distilled water and sodium dodecyl sulfate (SDS) as surfactant is evaluated for turning operation on Ti–6Al–4V workpieces. Turning operations were carried out under three different conditions – dry, with conventional cutting fluid and with nanofluid. Nanofluid application was limited to 1 L/h and it was applied at the tool tip through gravity feed. Various machining responses like cutting force, surface finish and tool wear were analyzed while turning at optimum cutting parameters as 150 m/min, 0.1 mm/rev and 1 mm depth of cut. Later on, machining performance of nanofluid is confirmed at low cutting speed of 90 m/min. Nanofluid outperformed conventional cutting fluid with 34% reduction in tool wear, average 28% drop in cutting forces and 7% decrease in surface roughness at cutting speed of 150 m/min.

Study on surface finish of AISI 2080 steel based on the Taguchi method

Surface finish and dimensional accuracy play a vital role in manufacturing engineering applications. Grinding is one of the most important methods for producing a better surface quality. This paper describes a study of the influences of cutting parameters such as table speed, depth of cut and feed rate on surface finish of AISI 2080 steels, based on the Taguchi (L27) method. The experimental results showed that the table speed was the machining parameter, which had a greater effect on the surface finish, followed by depth of cut, whereas feed rate showed no significant effect. Analysis of variance indicated that a better surface finish was obtained at 190 m/min speed, 0.003 mm depth of cut and 0.08 mm/rev feed rate.

Optimization of cutting parameters for surface roughness in turning of studs manufactured from AISI 5140 steel using the Taguchi method

Abstract This study focuses on optimizing cutting parameters based on the Taguchi method to minimize surface roughness in turning of studs manufactured from AISI 5140 steel. The Taguchi method, which is a powerful tool for designing optimized quality, is used to find the optimum surface roughness in turning operations. Rotational speed, feed rate and depth of cut were considered as control factors for the surface roughness, and L9 orthogonal array was determined for experiment trials. An orthogonal array, a signal-to-noise ratio, and an analysis of variance were employed to investigate the surface roughness characteristics of AISI 5140 steel. Minimum surface roughness was obtained at 2000 rpm rotational speed, 0.2 mm × rev−1 feed rate and 0.5 mm depth of cut. Optimal surface roughness was calculated as 1.70 μm by using optimal level of design parameters. Confirmation test showed that Taguchi method can be used precisely for optimizing the cutting parameters in turning of AISI 5140 steel. Through this study, it is possible to not only obtained the optimum surface roughness for turning operations, but also the main cutting parameters affecting the performance of turning operations. The developed model can be used in the metal machining industries in order to determine the optimum cutting parameters for minimum surface roughness.

Investigation of Neem Seed Oil as an Altanative Metal Cutting Fluid

Oil extracted from neem seed was investigated for use as alternative cutting fluid in metal machining operation using mild steel at three different values each of cutting speeds, depth of cut and oil ratios. Physicochemical properties that relate to cutting fluid’s performance like cooling effect (temperature rise) and surface roughness were measured and compared to those of conventional cutting oil bought from the market and also with data obtained in dry metal cutting experiment with no lubricant. Results indicated that neem had flash point of 157°C, pour point of +8°C, kinematic viscosity of 8.08cSt at 100°C. Specific gravity at 14/40°C was 0.9304, sulpur content was 0.0293%, pH was 5.6 and free fatty acid (oleic acid) was 5.94%. Cooling effect was found to be comparable at different oil ratios and speeds, but dry machined surfaces produced the least cooling effect with temperature rise of up to 57.33°C at 710rpm at 0.5mm depth of cut. However, neem was found to perform slightly better than the soluble oils in most of the test results. Surface roughness for neem, soluble oil and dry machining were in the range of 0.002 μm and 1.427 μm. The least surface quality was obtained with neem oil at a speed of 250 rpm; depth of cut of 1mm at 50% oil and 50% water mixture. However all surface roughness was within the recommended standard that is the acceptable value for turned and machined surfaces with maximum value set at 25μm.

Energy conscious cryogenic machining of Ti-6Al-4V titanium alloy

Manufacturing and, in particular, machining are responsible for a significant portion of global industrial energy consumption (25%). Previous research has shown that precise selection of cutting parameters can improve the energy consumption of machining processes. Cryogenic machining has attracted significant attention for improving the machinability of difficult-to-machine materials while also eliminating the environmental and health issues associated with the use of cutting fluids. Despite the advantages, there is a considerable research gap in cryogenic milling operations. This article investigates the effect of cryogenic cooling using liquid nitrogen in end milling of Ti-6Al-4V. A robust and rigorous methodology was developed and a series of machining experiments were conducted using a combination of cutting parameters repeated at dry, flood and cryogenic cooling environments. The investigations indicated that cryogenic cooling considerably reduce tool wear when compared to dry and flood cooling while allowing for using higher cutting speeds. The cutting tool used for cryogenic machining at 200 m/min cutting speed, 0.03 mm/tooth feed rate and 5 mm depth of cut showed minimum flank wear. Furthermore, the investigations demonstrated that using the machine’s coolant pump in flood cooling resulted in higher power and energy consumption than dry and cryogenic cooling. This article clearly shows that higher material removal rates are required in order to minimise specific machining energy. Therefore, since cutting speed is limited in dry machining, cryogenic machining is the most favourable as higher cutting speeds can be used. Using cryogenic machining at 200 m/min cutting speed resulted in an 88% reduction in energy consumption of the machine tool as compared to flood cooling at 30 m/min while minimum tool wear (10 µm) was detected. This clearly demonstrates the significant capabilities of cryogenic machining when compared with more conventional machining approaches.

FWTPET Investigation on SA213 Tube to SA387 Tube Plate

In this research work, an experimental investigation of Friction Welding of Tube to Tube Plate with External Tool (FWTPET) has been carried out using backing block arrangement with interference fit. The Materials have been used in this research of SA213 tube and SA387 tube plate. The results of the experimental investigation revealed that by employing backing block, FWTPET is capable of producing defect free welds. The Welding sample has been conducted several characteristics such as Compression test, radiographic test and Microscopic Test. Further Taguchi L9 orthogonal array was utilized to find the most significant control factors which will yield better joint strength. Besides, the contribution of each process parameter has been determined using statistical analysis of variance (ANOVA). The Input and Output values are 1320 rpm Speed, 0 mm projection, 0.1 mm Depth of cut and 3086.90 MPa optimal joint strength respectively.

A New Hybrid Approach to Optimize the End Milling Process for Al/SiC Composites using RSM and GA

The centre of research is to optimize the cutting Forces (F R ), surface Roughness (Ra) and Material Removal Rate (MRR) of end milling for Aluminium compositeusing Response Surface Methodology (RSM) and Genetic Algorithm (GA). The RSM L 31 empirical model is conducted with Al/SiC composites of various compositions. The cutting forces and the surface roughness are measured using 3-axis milling tool dynamometer and MarTalk Profilometer respectively. The second order mathematical models in terms of machining parameters are developed for predicting responses with adequacy above 85%. The optimal configuration of end milling are 5 wt. % of reinforcement, 0.3 mm depth of cut, feed rate of 49.3 mm/min and cutting speed of 474.3 rpm to acquire minimum FR, Ra with maximum MRR is done by Genetic Algorithm (GA). From the estimated model, the responses are with the experimental deviation of 11% MRR, 13% Ra and 17% FR for the desirability of 98.7%. The optimization of three machining parameters with a advance hybrid approach brought a new scope for the researchers and manufactures to improve the standard of automated machining.

Optimization of energy consumption response parameters for turning operation using Taguchi method

The environmental performance of machining operations can significantly be improved by reducing energy consumption of machine tools. The present research work focuses on the optimization of foremost energy consumption response parameters viz. energy efficiency (EE), active energy consumed by the machine (AECM) and power factor (PF). The consideration of PF as an important energy consumption response parameter becomes essential as the electricity boards/suppliers put penalties on the manufacturing units, if the PF is low. The optimization of PF can also reduce the cost of installation of PF correction equipment besides reduction in penalties. An experimental analysis is carried out for the CNC rough turning of EN 353 alloy steel with multi-layer coated tungsten carbide insert. The effect of important input process variables viz. cutting speed, feed rate, depth of cut and nose radius along with their interactions has been studied on these energy consumption response parameters. The Taguchi's L27 orthogonal array is used for design of experiments and to optimize the response parameters using MINITAB 16 software. The results reveal that optimum turning conditions for the PF and EE are same and occur at 248.69 m/min. cutting speed, 0.3 mm/rev. feed rate, 1.8 mm depth of cut and 0.8 mm nose radius. The optimized control factors setting for AECM are 248.69 m/min. cutting speed, 0.3 mm/rev. feed rate, 1 mm depth of cut and nose radius 1.2 mm. Results of ANOVA, have shown that the depth of cut is the most dominant input process parameter for PF and EE, and feed rate be the dominating vital parameter for reduction of the AECM. The nose radius does not contribute too much for energy consumption response parameters. The interactions between most of input variables are also not significant for energy consumption response parameters. At optimum turning conditions for each significant energy consumption response parameter viz. EE, AECM and PF achieved in the present study, there is an improvement of 61.776%, 57.025% and 7.49%, respectively compared to turning conditions in common use for rough turning.

Optimization of Multi-Responses in Hot Turning of Inconel 625 Alloy Using DEA-Taguchi Approach

In the present work DEA (data envelopment analysis) coupled with Taguchi method has used for optimization in process parameters of hot turning operation. An experimental investigation has been carried out to study the effect of cutting parameters such as speed, feed and depth of cut during. The material removal rate and surface finish, are to be studied with respect to machining at 450 temperature by heating Inconel 625. In order to achieve both quality and productivity, optimization of both is necessary simultaneously. DEA –Taguchi method can employed for solving in multi-response problem. LINGO software was used to find out the relative efficiency and converted to S/N ratio using MINITAB software. The optimization of the machining parameter found at 100 m/min cutting speed, 0.15 mm/rev feed rate and 1 mm depth of cut. Depth of cut is the most influencing parameter which affect both surface finish and material removal rate in the machining process.

Optimization in Hot Turning of Nickel Based Alloy Using Desirability Function Analysis

This paper presents a desirability function approach in order to find out an optimal combination of Machining parameters for multi-response parameters in hot turning operation of nickel based alloy. Taguchi’s L9 orthogonal array is used for experimental design. The machining parameters such as cutting velocity, feed rate, depth of cut and temperature are optimized by multi-response considerations namely power, flank wear, and MRR. ANOVA test was carried out and it was found that cutting speed is most influence parameter followed by feed rate, depth of cut and workpiece temperature. The optimization of machining parameters was found at 5.8 m/min of cutting speed, 30 °C preheating temperature, 0.2 mm depth of cut and 0.15 mm/rev feed rate

Parametric study and multicharacteristic optimization of rotary turning process assisted by longitudinal ultrasonic vibration

Turning with rotary tool is a newly developed alternative of the conventional turning process in which cutting edge of a round insert rotates about its axis, so that a continuously indexed cutting edge is fed into the cutting zone. In the present study, a longitudinal high-frequency vibration was superimposed to the rotary tool to analyze the cutting force and surface roughness of AA7075 during orthogonal cutting. However, due to contribution of wide ranges of factors in the vibratory-rotary turning process, the selection of optimal parameter setting is a challenge that is faced with this process. In the present work, an attempt was made to simultaneously minimize machining force ( Fz) and surface roughness ( Ra) through selection of the optimal setting of cutting velocity, feed rate, tool rotary speed in rotary turning, and vibratory-rotary turning operations. Here, grey relational analysis was used to find the optimal parameter setting in rotary turning and vibratory-rotary turning processes, separately. Then the obtained solutions were compared. Results indicated that applying axial vibration to the rotary tool turning significantly reduced both surface roughness and cutting force. From the optimization by the grey relational analysis method, it was obtained that for both rotary turning and vibratory-rotary turning operations, setting of 4 m/min cutting velocity, 220 r/min tool rotary speed, 0.08 mm/rev feed rate, and 0.3 mm depth of cut are the most-optimal solutions that causes minimum Fz and Ra, simultaneously. Also, the vibratory-rotary turning process had higher values of grey relational grade than the rotary turning process that implies outperformance of the vibratory-rotary turning with respect to the rotary turning process. The obtained results were then verified, compared, and discussed based on the mechanics of turning process.

Development and analysis of a consciously designed Joint Interface Module for improvement of a machining system’s dynamic performance

Machining vibrations and dynamic instability of machine tools is an important consideration in machining systems. Common approaches for improving their dynamic performance target either the process, or intelligent, yet complex control systems with actuators. Given that machine tools’ dynamic characteristics are largely defined by the characteristics of the joints, this article proposes a novel concept, attempting to create a new paradigm for improving the dynamic behaviour of machine tools—introducing modular machine tools components (Joint Interface Modules—JIMs) with joints deliberately designed for increasing dynamic stiffness and enhancing damping with the use of viscoelastic materials. Through a systematic model-based design process, a prototype replicating a reference tool holder was constructed exploiting viscoelastic materials and the dynamic response of the machining system was improved as a result of its introduction; in machining experiments, the stability limit was increased from around 2 mm depth of cut to 4 mm depth of cut, without compromising the rigidity of the system or changing the process parameters. The article also includes the results of investigations regarding the introduction of such prototypes in a machine tool and discusses the shortcomings of the stability lobe diagrams as a method for evaluating the performance of machine tool components with viscoelastically treated joints.

Multi-Objective Optimization in Hot Machining of Al/SiCp Metal Matrix Composites

Metal Matrix Composites (MMCs) have been found to be useful in a number of engineering applications and particle reinforced MMCs have received considerable attention due to their excellent engineering properties. These materials are generally regarded as extremely difficult to machine, because of the abrasive characteristics of the reinforced particulates. These characteristics of MMCs affect the machined surface quality and integrity. This paper presents use of Taguchi Grey Relational Analyses (GRA) for optimization of Al/SiCp/10p (220 and 600 mesh) MMCs produced by stir casting. Experiments are performed using L16 orthogonal array by using hot machining technique. The objective of this study is to identify the optimum process parameters to improve the surface integrity on Al/SiCp MMCs. The machined surface integrity has been analyzed by process parameters such as speed, feed, depth of cut and preheating temperature. The significance of the process parameters on surface integrity has been evaluated quantitatively by the analysis of variance (ANOVA) method and AOM plots. The grey relational analysis shows optimum machining conditions as 0.05 mm/rev feed, 0.4 mm depth of cut and 60 °C preheating temperature to enhance surface integrity for both Al/SiCp/10p (220 and 600 mesh) MMCs except for cutting speed 50 and 25 m/min respectively.

A Study on Ultrasonic Elliptical Vibration Cutting of Inconel 718

Inconel 718 is a kind of nickel-based alloys that are widely used in the aerospace and nuclear industry owing to their high temperature mechanical properties. Cutting of Inconel 718 in conventional cutting (CC) is a big challenge in modern industry. Few researches have been studied on cutting of Inconel 718 using single point diamond tool applying the UEVC method. This paper shows an experimental study on UEVC of Inconel 718 by using polycrystalline diamond (PCD) coated tools. Firstly, cutting tests have been carried out to study the effect of machining parameters in the UEVC in terms of surface finish and flank wear during machining of Inconel 718. The tests have clearly shown that the PCD coated tools in cutting of Inconel 718 by the UEVC have better performance at 0.1 mm depth of cut as compared to the lower 0.05 mm depth of cut and the higher 0.12 or 0.15 mm depth of cut. Secondly, like CC method, the cutting performance in UEVC increases with the decrease of the feed rate and cutting speed. The CC tests have also been carried out to compare performance of CC with UEVC method.

Double tool turning: machining accuracy, cutting tool wear and chip-morphology

In this work, turning was carried out in a lathe with two single point cutting tools mounted on the carriage, one at the front and the other at the rear side. The deflection due to one cutting tool is resisted by the other cutting tool. It also act as follower rest, apart from their primary role of material removal. For the cutting speed of 116 m/min, feed of 0.24 mm/rev and depth of cut of 1mm, the diametral error was reduced by 80%. Turning was also carried out at 1.5 mm and 2 mm depth of cut. The effective coefficient of friction of the rear tool was lesser than the front tool. However, the average surface temperature of the workpiece near the rear cutting tool was higher than that near the front cutting tool. This may be due to strain hardening. Tool wear and chip morphology was also studied.

Performance of Cu-Cr-Zr electrodes in electrical discharge machining of tungsten carbide composite material base using Taguchi method

The research aimed to study the performance of Cu-Cr-Zr electrode material in the electrical discharge machining (EDM) process of tungsten carbide WC90-Co10 grade using parameters such as duty factor, discharge current, and electrode polarity. The present work involves evaluation based on the effect of process parameters on material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR) of the EDM tungsten carbide process. The experiment used an electrode of 10 mm in diameter and 1 mm depth of cut for the EDM sparking process under a dielectric fluid. The results showed that the electrode negative polarity performed better than the positive polarity and the MRR stood at 1.76 mm3/min of 76% duty factor while the SR was 2.52 µm. Additionally, the effects of the parameters were found to be significant compared to other factors though the techniques predicted near similar results based on Taguchi's technique of ANOVA analysis.

EXPERIMENTAL STUDY OF DOUBLE POINT CUTTING TOOL ON CHIP – TOOL INTERFACE TEMPERATURE IN TURNING

A special type of a tool is designed and made to have two cutting points for turning long workpieces and it may be termed as the double point cutting tool. The double point cutting tool has two cutting points which has the height difference of 0.5 mm and the distance between them is 6 mm. So that when the first cutting point takes 0.5 mm depth of cut and next to that the second cutting point also takes 0.5 mm depth of cut as the tool proceeds for turning. Hence the total machining time is reduced considerably. Chip – Tool Interface Temperature takes very important role in metal cutting which decides the dimensional accuracy, mechanical properties of the workpiece and the tool life. Investigation on Chip – Tool Interface Temperature in HSS Double Point Cutting Tool during turning of Mild Steel for different cutting conditions is presented in this Research article.

Creep feed grinding of γ-TiAl using single layer electroplated diamond superabrasive wheels

The paper details machinability experiments involving creep feed grinding of Ti–45Al–2Mn–2Nb+0.8vol.% TiB2 intermetallic alloy using single layer electroplated diamond grinding wheels. A wheel speed of 35m/s and a feed rate of 150m/min were utilised along with two different grinding regimes; roughing with D252 and D126 wheels using a 1mm depth of cut and finishing using a D46 wheel and 0.1mm depth of cut. The roughing operation employing the D252 wheel gave a maximum G-ratio of ∼100 and a workpiece surface roughness of 2.94μm Ra. These reduced to ∼20 and ∼0.3μm Ra using the D46 wheel. Normal and tangential forces when roughing were up to 2500 and 500N, respectively. Grit pullout was mainly visible with the D252 wheel however; wear flats were evident with all three wheels. Workpiece surfaces produced using the D126 wheel showed burn levels increasing with material removed. Analysis of surfaces generated with the D252 wheel showed the presence of cracks and pullout/fracture with a width of up to 50μm and depth of 20μm, whereas finishing conditions resulted in understandably superior surface integrity with no visible damage. Similarly, a hardened layer of up to 625 HK and extending to a depth of ∼100μm was apparent when roughing but was absent during finishing.