Spindle Rotational Speed Research Articles

Analisis Kekasaran Baja AISI 304 Akibat Variasi Parameter pada Proses Roughing CNC Turning Menggunakan Pahat Cermet

Abstract: This study aims to determine the surface roughness value of AISI 304 steel due to variations in spindle speed and feed motion. The method used is pre-experimental design and data analysis techniques used are descriptive analysis techniques. The spindle rotation speed used is 1990 rpm, 2100 rpm, and 2300 rpm, while the feed motion used is 0.18 mm / rev, 0.23 mm / rev, and 0.28 mm / rev. The cutting tool used in this study is a Mitsubishi brand insert chisel with ISO standard CNMNG120404-MA, while the data collection technique using a measuring tool to measure the surface roughness of the workpiece is the Surface Roughness Test Mitutoyo Portable Surftest SJ 301 series. The results of this study indicate that high engine speed reaches 2300 Rpm and low feed motion reaches 0.18 mm / rev resulting in low surface roughness levels reaching 2.17 µm. While the highest is obtained at low engine speed and high feed motion which reaches 1900 Rpm and 0.28 mm / rev with a surface roughness value of 4.43 µm.Keywords: Spindle rotation, feed speed, turning, CNC lathe, surface roughness.

Effect of revolution speed on the mechanical properties of dissimilar Aluminum alloy joined by friction stir spot welding

Friction stir spot welding (FSSW) method was performed for welding of aluminum alloys AA6061-T6 with pure aluminum AA1100 sheets having thicknesses of 2.4 and 3 mm respectively. FSSW procedure was accomplished at varied tool rotational speeds (1000, 1600, and 2000 rpm). The dwell time was (2, 4, and 6 sec) and the geometry of the tool pin was threaded cylindrical pin with a cylindrical and straight shoulder.The aluminum alloy AA6061-T6 sheet was overlapped on the pure aluminum AA1100 sheet. The tensile shear test was investigated for all specimens. It was deduced that the value of the maximum shear force is 1.95 kN. This value was obtained at the following welding factors: 2000 rpm spindle rotational speed, 4 sec dwell time and threaded cylindrical pin profile, the two other factors which were pin length and plunging time were kept as constant parameters through the tests at 3.2 mm and 40 sec respectively. It was also concluded that the fracture happens in the nugget zone mode at the highest lap-shear load.

Mechanistic models for prediction of cutting forces and power consumption considering chip geometry

A novel approach for modeling and simulation of cutting force and power consumption in relation to chip geometry has been proposed in end milling‌ of AISI D2 steel. It is carried out in two stages: experimental work and finite element method based numerical simulation. In the first stage, experiments are conducted on the AISI D2 steel at two levels of spindle rotational speed, axial depth of cuts and four levels of feed per tooth using 10 mm and 8 mm diameter mill cutters. Cutting forces and amplitude of cutter vibration are measured in X and Y directions. Mechanistic models in terms of chip geometry and cutting force coefficients are developed to predict cutting forces and power consumption relative to chip geometry at 30°, 60° and 90° of cutter rotation. In the second stage, numerical simulation is carried out to predict cutting forces and power consumption relative to chip geometry at 30°, 60° and 90° of cutter rotation and compared with estimated values of cutting forces and power consumption. The maximum error between the two approaches for the cutting forces in X and Y directions and power consumption is estimated as 10.80%, 8.33% and 7.70% respectively. At spindle rotational speed of 2000 rpm, 0.3 mm of axial depth of cut and 50 µm of feed per tooth, the cutting forces and cutting power consumption are found minimum.

Transient separation cutting characteristic of axial ultrasonic vibration–assisted cutting

Axial ultrasonic vibration–assisted cutting has been proposed and proved preponderance on cutting performance; however, the transient separation cutting characteristic has not been clearly revealed. This paper focuses on the transient separation cutting characteristic of axial ultrasonic vibration–assisted cutting and its influence on the cutting performance. First, the separation cutting criteria, including feed coefficient and phase shift, are established and influence factors, such as feed rate, amplitude, and phase shift, are systematically analyzed. Subsequently, the duty ratio is deduced and calculated, and some features and a control mechanism are introduced. In addition, a transient separation cutting model with four stages is demonstrated. The reason for the average cutting force reduction by the transient separation cutting characteristic is also stated. Finally, the verification of the separation cutting and transient separation cutting model and the comparison of the feed thrust force and parameter influences on the cutting performance are experimentally performed. The transient signals of different duty ratios 0.55 to 1 are obtained, and 10 to 40% reductions of feed thrust are measured both by a PCB sensor and a Kistler dynamometer. The influence degree of the feed coefficient, spindle rotation speed, and cutting depth on the performance is analyzed. A parameter combination of smaller feed coefficient, moderate spindle rotation speed, and smaller cutting depth is suggested to obtain a better cutting performance by fully considering the cutting force, surface roughness, and tool life.

Influence of rheology and activation energy on the structure of protective coatings formed from CMC suspensions with Al powder

Influence of the temperature and rotation speed of the viscometer spindle on the rheological properties of CMC-based suspensions with aluminum powder is considered. It is shown that suspensions belong to pseudoplastic systems. It is established that, with an increase in the activation energy of viscous flow in CMC-based suspensions, the intensity of intermolecular interactions between polymer macromolecules and oxide shells of Al microparticles increases. Using infrared and scanning microscopy, the structure and morphological features of coatings formed from suspensions are studied. It is revealed that the structure hardening of composite coatings occurs due to hydrogen bonds available for interaction in the OH groups of an aqueous solution of CMC.

Computational-experimental research of the stiffness of high-speed spindles

The stiffness indices of high-speed spindle units on angular contact ball bearings at high rotational speeds are investigated. It is found, that the spindle rotational speed, radial load, bearing temperature, type and magnitude of the preload in the bearings significantly affect the stiffness of the spindle unit. Keywords: high-speed spindle unit, angular contact ball bearing, elastic-deformation model. i.a.zverev@stankin.ru

Development of variable preload system for machine tool spindle using giant magnetostrictive material Terfenol-D actuator

Applying a bearing preload of machine tool spindle produces positive effects, including increased stiffness, rotation noise reduction, increase in shaft precision, position adjustment during operation, and prevention of rolling element resonance and rotating slip, along with a significant extension of the bearing lifespan. A variable preload technique is a method that improves the bearing performance by appropriately varying the preload applied to the bearing according to the spindle rotation speed and machining condition. In this study, a novel variable preload method utilizing a Terfenol-D actuator has greater power and more displacement and force than those of other transducer materials such as piezo elements or nickel alloys. Terfenol-D has greater power and more displacement and more force. A prototype of a spindle for the variable preload system using Terfenol-D was fabricated, and the axial force and displacement of the bearing were measured during a running experiment. In order to assess whether the proposed variable preload device can effectively apply preloading to the bearing, a comparative analysis was conducted between the theoretical and empirically obtained values of the bearing axial direction displacement. Through the comparative analysis, the real applicability of the proposed structure was confirmed.

Behavioral studies of process parameters and transient numerical analysis on friction stir welded dissimilar alloys

Friction stir welding is a solid state technique in which welded joints are performed using non-consumable tool to heat the metal to plasticized state. The tool exerts high friction and sustained stirring over the metal substrate resulting in a sound weld. In the present work, influence of various process parameters on dissimilar welding of AA 6061 T6 and AA7075 T651aluminium alloys is investigated to enhance the strength properties. Cylindrical and Conical tool pin geometries are chosen to prepare butt welded joints. The tool geometry, rotational spindle speed and feed rate are the various process variables considered for the study. The ultimate tensile strength (UTS) and elongation for six welded joints are determined with rotational spindle speed of about 600, 800, 1000 RPM and feed rate of about 30, 45, 60 mm/min respectively. Irrespective of the process parameters, it is observed that, cylindrical tool rendered the better tensile and elongation property compared to the conical tool. Transient Finite Element Analysis is employed for non-linear problem in the Coupled Eulerian-Lagrangian Formulation. The parametric model with base weld plates and the tool is performed using ABAQUS software. Experimental strength results were validated with Finite Element Analysis. The corresponding strain, deformation and nodal temperature values were determined.

Application of the Combined ANN and GA for Multi-Response Optimization of Cutting Parameters for the Turning of Glass Fiber-Reinforced Polymer Composites

Glass fiber-reinforced polymer (GFRP) composites find wide applications in automobile, aerospace, aircraft and marine industries due to their attractive properties such as lightness of weight, high strength-to-weight ratio, high stiffness, good dimensional stability and corrosion resistance. Although these materials are required in a wide range of applications, their non-homogeneous and anisotropic properties make their machining troublesome and consequently restrict their use. It is thus important to study not only the machinability of these materials but also to determine optimum cutting parameters to achieve optimum machining performance. The present work focuses on turning of the GFRP composites with an aim to determine the optimal cutting parameters that yield the optimum output responses. The effect of three cutting parameters, i.e., spindle rotational speed (N), feed rate (f) and depth of cut (d) in conjunction with their interactions on three output responses, viz., Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface roughness (Ra), is studied using full factorial design of experiments (FFDE). The statistical significance of the cutting parameters and their interactions is determined using analysis of variance (ANOVA). To relate the output response and cutting parameters, empirical models are also developed. Artificial Neural Network (ANN) combined with Genetic Algorithm (GA) is employed for multi-response optimization to simultaneously optimize the MRR, TWR and Ra.

Pengaruh Parameter Pemotongan CNC Milling dalam Pembuatan Pocket terhadap Getaran dan Kekasaran Permukaan pada Crankcase Mesin Pemotong Rumput

The purpose of the research is to find and prove the influence of machining parameters on vibration and roughness in the pocket milling process. The experimental method is used to improve the quality of products produced by CNC milling, the parameters used in the study are spindle rotation speed with variations of 300 rpm, 1200 rpm, and 3200 rpm, the depth of feed used is 2 mm and 0.5 mm. Then the test is carried out with a vibration test and surface roughness test. The data analysis technique used is descriptive statistics. The results obtained are the use of machining parameters affect the quality of the product in terms of roughness and vibration of the engine, with higher spindle rotational speed resulting in lower roughness values. The smaller the depth of feedings, the finer the roughness, then the higher the spindle rotation speed, then vibration will be lower, then the greater the depth of feed, the higher the vibration value.

Enhanced magnetic abrasive finishing of Ti–6Al–4V using shear thickening fluids additives

The available magnetic field assisted finishing process is considered as the critical stage for improvement of workpiece surface quality. This paper aims to investigate the key quality performance of an enhanced magnetic abrasive finishing in achieving nanolevel finish on Ti–6Al–4V workpieces with initial micrometer surface roughness values. The finishing media, combining the intelligent shear thickening fluids (STFs), carbonyl iron particles and SiC particles, is developed. Finishing experiments for Ti–6Al–4V workpieces are conducted using an established platform, aiming to investigate the effects of varying STFs concentration, working gap, feed rate and spindle rotational speed. It is observed from the experimental results that the developed finishing media is effective for surface finishing comparing to the finishing media without STFs. The surface roughness of 54 nm was achieved from the initial value of 1.17 μm, which improved by over 95%, under the experimental conditions of 0.8 mm working gap, 15000 mm/min feed rate, 900 rpm spindle rotational speed and 15 wt% STFs. Surface observations showed that a smooth surface without obvious scratches was obtained.

Research about the influence of the parameters of the polishing pad on the removal depth of the Al6061 material

Polishing pressure, machining dwell time and tool head spindle speed are the main factors affecting the workpiece cutting depth. In order to analyze the importance of influencing factors, the orthogonal experiment is conducted. The pre-processing is carried out first, and then the formal processing is started. After the formal processing is completed, the cutting depth of each processing point is measured, and the cutting depth under the specified parameters is obtained by subtracting the cutting depth obtained from the pre-processing. Finally, the experimental data show that the average cutting depth is taken as evaluation criteria, and the most important influencing factor is dwell time, followed by polishing force, and spindle rotation speed.

Investigation of ultrasonic vibration on thrust force, surface integrity, and geometrical tolerances during drilling of natural filler reinforced composites

Growing global environmental threats have attracted researchers and engineers toward design and manufacture of green materials. In this regard, natural filler reinforced composites are environmentally friendly, cost-effective materials with a lot of advantages over conventional carbon/glass fiber reinforced composites. Hence, in this study, the drilling performance of walnut shell powder reinforced composite material was experimentally investigated. For this purpose, the composite specimens were first fabricated by injection molding process, followed by further drilling tests, which were performed with and without ultrasonic vibration. The effect of drilling parameters and ultrasonic vibration was investigated on surface roughness, thrust force and geometrical tolerances (circularity and cylindricity), as the process performance parameters. The obtained results demonstrated that by increase of the spindle rotational speed and decrease of feed rate, the thrust force, surface roughness and geometrical tolerances were reduced. Also, it was seen that ultrasonic vibration could effectively enhance the performance parameters, which was attributed to the intermittent cutting process and impact action of ultrasonic vibration, leading to reduced friction, improved material removal, reduced cutting forces, and better surface quality.

Influence of Curvature and Cross-sectional Shape of Cylindrical Surface Formed by Turning on Its Roughness

The cross-sectional curvature and shape (inner and outer) of a cylindrical surface formed by turning have an effect on the roughness parameter—the arithmetic mean deviation of the Ra profile. The main regularities in this influence are analyzed in this article. The authors investigated specially designed test specimens using their own method, which excludes the influence of other parameters on the roughness forming process. The diameters of the cylindrical surfaces of test specimens were selected taking into account the spindle rotation speed of the lathe. As a result, these surfaces were machined at practically the same cutting speed when performing the final processing step. The Grebbs criterion was used to evaluate the uniformity of surface roughness obtained experimentally.

Pengaruh Cairan Pendingin Terhadap Kekasaran Permukaan Benda Kerja Pada Proses Face Milling

Coolant is one of the factors that affects the quality of the workpiece. The selection of coolant is useful to lower the surface roughness of the workpiece. In addition, coolant should be easily degradable in the environment so that the environment is not polluted. Example coconut oil is an oil that can be degraded in the environment. This research is aimed to observe the influence of coconut oil for cooling to the surface roughness obtained during face milling process. In the experimental tests, conventional milling machine was used and the milling tests were performed under various machining parameters, namely spindle rotational speed was 360 and 490 rpm, feeding speed was 60 mm/min and 70mm/min. Based on the result, the surface for spindle rotational speed of 360 rpm and feeding speed 60 mm/min was more rough than one in spindle rotational speed of 360 rpm and feeding speed 70 mm/min. Besides, the surface roughness for spindle rotational speed of 490 rpm and feeding speed of 60 mm/min was also more rough than one in spindle 490 rpm and 70 mm/min.

Force compensation for precise positioning in machine tools via state observer design

In machining, cutting force generated is identified as input disturbance to the servo drive systems of the positioning table. In frequency domain, the cutting force magnitudes can be synthesized according to various harmonic components depending on the cutting tool spindle speed rotation. This paper focuses on compensation of high-frequency harmonic components of the cutting force using a state estimator named disturbance force observer (DFO) which explicitly estimates the input disturbance force. The force estimation error and tracking performances of the state estimator and the cascade P/PI positioning controller were analyzed experimentally on a single axis ball screw driven positioning table resembling a milling machine. The cascade P/PI controller was designed using traditional loop shaping frequency domain method while the force observer simultaneously estimated the input disturbance force based on the fundamental frequency dictated by the spindle rotational speeds. In experimental validations, a single, double, and triple harmonic-based force observers were designed at fundamental frequencies of 0.2 Hz, 0.5 Hz, and 0.8 Hz, and at amplitudes of 0.5 mm, 0.3 mm, and 0.2 mm, respectively. In time domain, the tracking performances of the system were analyzed and evaluated using root mean square of the position errors (RMSE) while in frequency domain, fast Fourier transform (FFT) analyses were performed on the tracking error signals. Results of the spectral analyses showed a 99.82% (single harmonic), 99.87% and 98.79% (two harmonics), and 99.83%, 97.13%, and 99.18% (three harmonics) reduction in respective force component magnitudes indicating close to successful estimation of the disturbance force observer. Meanwhile in time domain, numerical results of RMSE values showed reductions of 94.82%, 96.83%, and 94.01% for the three different input disturbance configurations while the experimental result showed reduction of 96.10%, 92.76%, and 92.44%, respectively. The work is to be expanded to include actual measured cutting forces as the input disturbance.

Effect to the Surface Composition in Ultrasonic Vibration-Assisted Grinding of BK7 Optical Glass

Because of the changes in cutting conditions and ultrasonic vibration status, the proportion of multiple material removal modes are of uncertainty and complexity in ultrasonic vibration-assisted grinding of optical glass. Knowledge of the effect of machined surface composition is the basis for better understanding the influence mechanisms of surface roughness, and also is the key to control the surface composition and surface quality. In the present work, 32 sets of experiments of ultrasonic vibration-assisted grinding of BK7 optical glass were carried out, the machined surface morphologies were observed, and the influence law of machining parameters on the proportion of different material removal was investigated. Based on the above research, the effect of surface composition was briefly summarized. The results indicated that the increasing of spindle rotation speed, the decreasing of feed rate and grinding depth can improve the proportion of ductile removal. The introduction of ultrasonic vibration can highly restrain the powdering removal, and increase the proportion of ductile removal. Grinding depth has a dominant positive effect on the surface roughness, whereas the spindle rotation speed and ultrasonic amplitude both have negative effect, which was caused by the reduction of brittle fracture removal.

Investigations on strain distribution, stress-based fracture limit and corrosion behaviour of titanium Grade 2 sheets during single point incremental forming

Purpose The purpose of this paper is to investigate the strain distribution, stress-based fracture limit and corrosion behaviour of titanium Grade 2 sheets during single point incremental forming (SPIF) process, with various computerized numerical control (CNC) spindle rotational speeds and step depths. The development of corrosion pits in 3.5 (%) NaCl solution has also been studied during the SPIF process. Design/methodology/approach A potentiodynamic polarization (PDP) study was performed to investigate the corrosion behaviour of titanium Grade 2 deformed samples, with various spindle rotational speeds in 3.5 (%) NaCl solution. The scanning electron microscope (SEM) and transmission electron microscope (TEM) analysis was carried out to study the fracture behaviour, dislocation densities and corrosion morphology of deformed samples. Findings The titanium Grade 2 sheets exhibited better strain distribution, fracture limit and corrosion resistance by increasing the CNC spindle rotational speeds, tool diameters and vertical step depths (VSD). It was recorded that varying the spindle speed affected plastic deformation which in turn affected corrosion rate. Research limitations/implications In this study, poor corrosion rate was observed for the as-received condition, and better corrosion rate was achieved at maximum speed of 600 rpm and 0.6 mm of VSD in the deformed sheet. This indicates that corrosion rate improved with increase in the plastic deformation. The EDS analysis report of corroded surface revealed the composition to be mainly of titanium and oxides. Practical implications This study discusses the strain distribution, stress-based fracture limit and corrosion behaviour by using titanium Grade 2 sheets during SPIF process. Social implications This study is useful in the field of automobile and industrial applications. Originality/value With an increase in the spindle rotational speeds and VSD, the titanium Grade 2 sheets showed better strain distribution, fracture limit and corrosion behaviour; the same is evidenced in fracture limit curve and PDP curves.

Experimental investigations on magnetic abrasive finishing of Ti-6Al-4V using a multiple pole-tip finishing tool

Surface finishing plays a critical role in product manufacturing. This paper aims to evaluate the magnetic abrasive finishing (MAF) process in achieving nano-finishing on Ti-6Al-4V workpiece. An improved finishing tool–integrated multiple pole-tip is fabricated to perform the surface finishing of Ti-6Al-4V workpieces. Finite element analysis of the variation of magnetic field intensity in the finishing region demonstrates obvious formation of magnetic brush based on the simulation model. The simulation results are confirmed by experimental measurements, where it shows a good agreement. Finishing experiments for Ti-6Al-4V workpieces are carried out using an established platform, aiming to investigate the effects of varying the spindle rotational feed, the rotary table speed, and the working gap on surface roughness (Ra). The surface roughness of 0.073 μm was achieved from the initial 1.195 μm based on the finishing parameters of 900-rpm spindle rotational speed, 160 r/min rotary table speed, and 0.7-mm working gap, which improved by over 94%. The surface quality was improved significantly with scratch reduction.

Influence of drag finishing parameters on the cutting edge radius of solid carbide mills

Paper deals with the cutting-edge preparation of milling tools by drag finishing. The aim of the experiment was to determine the optimal parameters of the process on a prototype device for edge preparation. The prototype device was based on a 3-axis milling centre and the drag finishing media used was Al2O3 granulating. Tools for the experiment were manufactured on a tool grinding machine Reinecker WZS 60 from the cemented carbide rod with chemical composition WC+Co (10%). After that, the tools were drag finished. Then, cutting edges radii were measured on a Zeiss SURFCOM 5000 surface and form measuring machine. The effect of process parameters such as spindle rotation speed, feed rate and time of the drag finishing on the size of the cutting-edge radius and shape was examined. The experiment design was described as well as measurement and evaluation of the output values. Purpose of the experiment and multi-criteria analysis described in this article was to determine the influence of process parameters on the cutting-edge radius sizes when drag finishing the cemented carbide mills.