Surface Roughness Of Machined Parts Research Articles

Performance of TiAlN PVD coated carbide tool in machining AISI 4340 with Minimum Quantity Lubrication (MQL) condition

There are several ways to assess machinability, viz. forces that are working during machining, the surface roughness of machined part, chip formation, and tool performance. This article aims to observe the machinability from the tool performance perspective when machining with minimum quantity lubrication (MQL). The MQL device can either be time-controlled or temperature-controlled using an Arduino. The machining was carried out on a conventional lathe toward a bar of AISI 4330 using carbide coated insert tools. The experiments were carried out using Taguchi design L9, by the varying depth of cut, coolant composition and method of applying the coolant. Tool performance was evaluated by tool deterioration value. There are four levels of tool deterioration according to its severities after machining. Analysis of variance shows that depth of cut more influence to the tool performance than the coolant application method by 32.69% and 12.82% each, respectively. However, it is proof that MQL with temperature-controlled would contribute to the minimum tool deterioration.

Influence of DLC Coatings Deposited by PECVD Technology on the Wear Resistance of Carbide End Mills and Surface Roughness of AlCuMg2 and 41Cr4 Workpieces

The primary purpose of this work was to study the effectiveness of using diamond-like coatings (DLC) to increase the wear resistance of carbide end mills and improve the surface quality of the processed part when milling aluminum alloy and low-carbon steel. The functional role of forming an adhesive sublayer based on (CrAlSi)N immediately before the application of the external DLC film by plasma-enhanced chemical vapor deposition (PECVD) technology in the composition of a multicomponent gas mixture containing tetramethylsilane was established in the article. The article shows the degree of influence of the adhesive sublayer on important physical, mechanical, and structural characteristics of DLCs (hardness, modulus of elasticity, index of plasticity, and others). A quantitative assessment of the effect of single-layer DLCs and double-layer (CrAlSi)N/DLCs on the wear rate of end mills during operation and the surface roughness of machined parts made of aluminum alloy AlCuMg2 and low-carbon steel 41Cr4 was performed.

Improving the machinability of leaded free cutting steel through process optimization

Free cutting steel grades are high sulphur grades which can be classified under two categories as Leaded and Non-Leaded. These grades are used for manufacturing components like Nuts, bolts, studs, hydraulic fittings, brake pistons where higher machining is required to get intricate shape. Machinability of these grades are affected by hard oxide inclusions and highly deformed manganese sulphide inclusions. At JSW, machinability of leaded free cutting steel is improved by various process modifications namely deoxidation through carbon and manganese, Tellurium (Rare earth element) addition and maintaining the oxygen level at 80- 120ppm. Former one avoids the formation of hard SiO2 and Al2O3 compounds, Tellurium addition forms PbTe compound at the tail of MnS inclusions which resists the deformation of MnS inclusions and increased oxygen level favours the formation of less deformable oxy- sulphide inclusions. Above process modifications have resulted in achieving the low silicate content, better aspect ratio of MnS inclusions in the final rolled product. They are assessed by the characteristics of chip formation and surface roughness of machined part.

Effects of Process Parameters on Surface Quality in Turning of Mild Steel with Rotary Cutting Tool

In machining processes, great amount of the cutting energy transforms to heat energy. Tool life decreases and the quality of the machined surface changes by the effects of heat during machining. Many researches are being done on the reduction of the negative effects of the heat on the tool. In this respect, cutting fluids are used, but usages of them are limited because of their some harmfully effects to the environment. In order to reduce the tool wear and to use the tool longer, during cutting continuously variation of the contact region of the tool and the chip can been realized by using self-propelled rotary tools. The tool life is longer in rotary tools when compared with stationary cutting tools. In machining with these tools lower heat effect at the cutting edge is observed. In this study, the effects of cutting parameters on surface roughness of machined part has been investigated during the turning of mild steel using self-propelled rotary tools. In experiments, cutting tools which inclination angles were 20°, 30° and 45° and rake angles were 0° and-5° were used. Cutting speeds were taken as 60 m/min and 120m/min. RCMX insert with 32mm diameter was used. Feed were chosen as 0.1, 0.2 and 0.4 mm/rev and cutting depth was set at 0.25 mm.

Effects of Process Parameters on Surface Quality in Turning of Mild Steel with Rotary Cutting Tool

In machining processes, great amount of the cutting energy transforms to heat energy. Tool life decreases and the quality of the machined surface changes by the effects of heat during machining. Many researches are being done on the reduction of the negative effects of the heat on the tool. In this respect, cutting fluids are used, but usages of them are limited because of their some harmfully effects to the environment. In order to reduce the tool wear and to use the tool longer, during cutting continuously variation of the contact region of the tool and the chip can been realized by using self-propelled rotary tools. The tool life is longer in rotary tools when compared with stationary cutting tools. In machining with these tools lower heat effect at the cutting edge is observed. In this study, the effects of cutting parameters on surface roughness of machined part has been investigated during the turning of mild steel using self-propelled rotary tools. In experiments, cutting tools which inclination angles were 20°, 30° and 45° and rake angles were 0° and-5° were used. Cutting speeds were taken as 60 m/min and 120m/min. RCMX insert with 32mm diameter was used. Feed were chosen as 0.1, 0.2 and 0.4 mm/rev and cutting depth was set at 0.25 mm.