Values Of Feed Rate Research Articles

Experimental investigation of cutting temperature during drilling of float glass specimen

In today’s industrialization, hard and brittle material such as float glass are widely used in various applications such as micro-fluidic devices, bio-medical parts, automotive glass, and optical lenses. Due to its difficult-to-machine characteristic, drilling of float glass leads to defects related to drilled hole quality. These defects exemplify as chipping, crack and surface roughness. All these defects are directly depend upon the temperature which could affect the drilling quality. Hence, authors tried to investigate the influence of cutting temperature of float glass specimen using rotary ultrasonic drilling. The experimentation is performed at two conditions with constant value of ultrasonic amplitude (20 μm), feed rate (6 mm/min) and spindle rotation speed (5000 rpm). These conditions are without coolant and with-coolant drilling. It is noticed that maximum cutting temperature reached with coolant drilling is 50.56°c and without coolant is 62.11°c. Consequently, it is revealed that drilling with coolant (water) should be adopted to improve the hole quality. Since, it reduced the formation of stresses during drilling operation which are induced due to rise in temperature. Microstructure images are carried out to visualize the hole quality.

Experimental setup development and parametric study of electrochemical face grinding process using Ni-based superalloy

Electrochemical grinding (ECG) process is an advanced machining process in which electrochemical action is used to remove the material from the workpiece atom by atom. Mechanism of metal removal in ECG is same as in case of ECM. In ECG, tool is used in the form of disc and rotating at certain rpm while in ECM, the solid sinking tool is used. Electrochemical face grinding (ECFG) process is one of the variants of ECG process in which axis of tool (disc shape) is perpendicular to the workpiece surface and material is removed due to electrochemical action between face of the wheel and workpiece surface. This process can be used for machining flat surfaces which are difficult to machine by conventional machining processes. In this study, a new set up of ECFG process is developed and then experimental study has been done using one-parameter-at-a-time (OPAT) approach. The experimental results suggest that both response parameters, surface roughness (Ra) and material removal rate (MRR) increases with elevated values of electrolyte concentration, feed rate and voltage. MRR also increases with wheel speed while Ra decreases with wheel speed.

Defi ning of strain non-uniformity during rods forging on lever-type radial-forging machine

The results of the strain non-uniformity in the forging of rods on the radial-forging machine by using FE modeling are presented. Comparative analysis of the strain non-uniformity distribution in the fi nal product for the rods forging on the lever-type radial-forging machine and the swaging machine and for different values of feed rate of the rod to the lever-type radial-forging machine is carried out.

Influence of Macerated and Cold Press Wheat Germ (Triticum vulgare) Oils Added at Different Rates to Trout Feed on The Feed Rate (FCR), Haemotology Parameters and NBT (Nitroblue tetrazolium) Values of Rainbow Trout (Oncorhynchus mykiss)

In this study, 2% of macerated and cold press wheat germ oils were added to the feeds of rainbow trout (average weight of 39.8 ± 4 g). At the end of the study, growth rate, blood parameters and NBT (Nitro blue tetrazolium) level of rainbow trout were determined. Feed Conversion Ratios (FCR) of groups were determined as macerated: 1.12, cold press: 1.53, control: 1.11. Statistically significant differences were found in red blood cell (RBC), hemoglobin (HGB), hematocrit (HCT), white blood cell (WBC), platelet (PLT) values (p<0.05). There was no statistically significant difference between Nitroblue Tetrazolium (NBT) levels (p>0.05).

Optimization of cutting parameters with respect to roughness for machining of hardened AISI 1040 steel

Abstract Today, energy consumption and environmental issues are important topics in all industries around the globe. However, quality is in direct proportion with energy consumption, since better surface finish means more energy consumption. The main objective of this work is minimizing both surface roughness and power consumption by estimating the optimum machining parameters. In this study, turning tests were carried out on three different hardened AISI 1040 steels (10, 15, 20 HRC) at three different depths of cuts (1.2, 2.4, 3.6 mm), feed rates (0.15, 0.25, 0.35 mm × rev−1) and cutting speeds (120, 140, 160 m × min−1) without coolant. The effects of cutting parameters and workpieces hardness on surface roughness, sound level and power consumption were examined. These analyses were conducted using a full factorial experimental design method. The response surface methodology and analysis of variance were also used to determine the effects of input parameters on the response variables. Experimental results showed that an increase in the feed rate value causes an increase in the surface roughness, the sound level, and the power consumption values. The results of the presented work show that feed rate is the most effective machining parameter that affects surface roughness and power consumption. Following feed rate, depth of cut and cutting speed also have an important impact. Thus, decreasing the value of feed rate and depth of cut will reduce the amount of power consumption.

Simulating the effect of depth of cut and feed rate on the force components in face milling

This paper presents a study about the workpiece force components (Fx, Fy, Fz) changes in face milling, which results from changing the depth of cut and the feed rate values. The values of the three force components in the face milling operation were found through the FEA-software AdvantEdge by Third Wave Systems. This program is uniquely intended for modelling of cutting processes. Simulations were carried out within five different cutting depth of cut and feed rate, to compare the obtained values and find out the results of the impact of changes on the three force components.

Response Surface Methodology (RSM) based analysis for tool life optimization in cryogenic CO2 milling of Inconel 718

This study presents the tool life optimization of carbide coated ball nose milling inserts using high-speed milling Inconel 718 under cryogenic CO2 environment. A total of 29 experiments were conducted based on Box-Behnken Response Surface Methodology using the 4 factors; cutting speed (Vc: 120-140 m/min), feed rate (Fz: 0.15-0.25 mm/tooth), axial depth of cut (ap: 0.3-0.7 mm), and radial depth of cut (ae: 0.2-0.6 mm) at three levels each. By using ANOVA, it was found that all factors have significant effects on tool life. However, the feed rate shows its highest influence on the tool performance where the tool life can be lengthened by reducing the feed rate values. After that, the relevant influencing parameters on tool life were derived in the form of mathematical model which was then used to predict the response within the predetermined parameters. With an average error of 8.2% between the predicted and actual tool life, it confirms the adequacy of the model in this research. ANOVA also suggests a tool life of 23.40 min could be obtained at optimized parameters of; Vc: 120.06 m/min, Fz: 0.15 mm/tooth, ap: 0.66 mm and ae: 0.53 mm under cryogenic CO2 condition.

Cold Spinning of Nimonic 75 Parts: Microstructure Evolution and Heat Treatment

Nimonic 75 sheets were cold-spun under different processing conditions and then heat-treated. The microstructure evolutions occurring during the process were studied and discussed in details. The results obtained showed the feasibility of the process when adopting low values of the tool feed rate. Metal spinning produces a deformed microstructure, different in the several areas of interest of the final component. The chosen heat treatment promoted the annealing of the material across the whole part.

The influence of variable feed rate on bushing and surface roughness in friction drilling

In this study AISI 1010 square-section material was drilled on CNC milling machine using friction drilling processes in two different patterns, namely constant feed rate and variable feed rate. In both drilling processes the tool–workpiece contact region temperatures, drilling forces, surface roughness and bushing profiles were examined. The drilling processes with constant feed rate used 50, 100 and 150 mm/min feed rate values. In drilling processes with variable feed rate, the feed rate values were increased constantly from 50 mm/min to 100, 150 and 200 mm/min during drilling. According to experiment results, in drilling with variable feed rate, tool–workpiece contact area temperature and bushing height increased. It has been witnessed that in the two different low feed rate drilling processes, no significant difference occurred in the petal structure of bushing. In 50–100 mm/min variable feed rate which provided the best bushing and petal structure, drilling time was reduced some 50% compared to drilling with 50 mm/min constant feed rate.

Investigation the Influence of SPIF Parameters on Residual Stresses for Angular Surfaces Based on Iso-Planar Tool Path

Incremental Sheet Metal Forming (ISMF) is a modern sheet metal forming technology which offers the possibility of manufacturing 3D complex parts of thin sheet metals using the CNC milling machine. The surface quality is a very important aspect in any manufacturing process. Therefore, this study focuses on the resultant residual stresses by forming parameters, namely; (tool shape, step over, feed rate, and slope angle) using Taguchi method for the products formed by single point incremental forming process (SPIF). For evaluating the surface quality, practical experiments to produce pyramid like shape have been implemented on aluminum sheets (AA1050) for thickness (0.9) mm. Three types of tool shape used in this work, the spherical tool gave higher residual stresses than other types, also three levels for each of step over and feed rates utilized. It found that residual stresses was raised up with increasing the step over and feed rate values, the effect of these variables studied on two slope angles. By using analysis of variance method (ANOVA) found that the most influential parameter is step over with (59.18%) and (65.42%) for both slop angles; (α=45°) and (α=55°) respectively. 

An Integro-Differential Equation with Variable Delay Arising in Machine Tool Vibration

We rigorously derive an integro-differential equation as a model for the possible onset of regenerative chatter during a turning process using a lathe. The cut is made parallel to the axis of rotation of the spindle. The model allows the spindle speed to continuously vary with time, which results in the presence of a variable time delay determined from a threshold condition. We present a number of conditions sufficient for the elimination of chatter; these emphasize sufficiently low feed rate or sufficiently high spindle speed. Numerical simulations cast light on the effect of a sinusoidally varying spindle speed, a feature of some modern lathes. Spindle speed variation can cure chatter but does not necessarily do so and can fail at higher values of the tool feed rate.

Minimum Quantity Lubrication System for Metal-Cutting Process: Sustainable Manufacturing Process

Abstract The purpose of this paper is to deliver a review of the implementation of the minimum quantity lubrication (MQL) system for manufacturing method, centring on the application of the MQL during the metal-cutting of workpiece. The application of MQL system was implemented & studied by various eminent investigators in last two decades. Thus, in this paper, experimental investigations of prior research work were discussed and analysed to light on review with significant facts for investigators and industries to optimize the metal-cutting process. During metal-cutting process, previous investigators considered three independent parameters like cutting speed, depth of cut and feed rate. Out of these parameters, feed rate was found to be most influencing parameter for response variables. But, for specific metal-cutting operation specific types of feed rate is required. Hence, the selection of optimum value & type of feed rate for specific machining operation is yet to investigated. This paper explored an evaluation of industry-socio based trial and error approaches and propose scope for improvement from both an economic and an environmental viewpoint. This paper delivers an outline of formerly conducted analysis to propose zones of enhancement in metal-cutting process employing minimum quantity lubrication system

Theoretical investigation of the effect of surface roughness on the fatigue life of austenitic stainless steels

After manufacturing, surface quality varies according to the type of manufacturing and cutting parameters. In this study, surface roughness measurements were performed after turning AISI 308 stainless steel in different machining parameters. Test samples prepared from steel in diameter 40 mm, length 200 mm were processed in CNC lathe machine in different cutting parameters. The highest roughness values were used for calculating the cross-sectional areas between the peak-valley points on surface profile. Using these roughness profile area values, theoretical fatigue life was calculated and evaluated due to the surface roughness. As a result, surface roughness tends to decrease with increasing cutting speed and theoretical fatigue life values have increased. The surface roughness has increased with the feed rate and fatigue life limit values have decreased.

Evaluation of Surface Roughness and Tool Wear in High Speed Machining of Inconel 718

This research work considered the high speed milling operation of Inconel 718 using a 4 flute solid carbide end mill tool without the use of coolant. Inconel 718 is a Nickel based Heat Resistance Super Alloy (HRSA) that is vastly used in the aerospace industries due to its excellent corrosion resistance and good mechanical properties. However, Inconel 718 is considered as a difficult-to-cut super alloy, which poses several problems when machining the material. The aim of this work is to investigate the effect and the influence of cutting parameters (feed rate, spindle speed, and depth of cut) on the quality of the machined surface as well as to evaluate the tool wear after machining. This evaluation of the surface roughness was done using a CNC milling machine at various parameters range for the values of feed rate (50-150 mm/min), spindle speed (2000-4000 RPM), and depth of cut (0.05-0.1 mm). The experiment was designed using Response Surface Analysis Method with Central Composite Design (CCD) to optimize the experimentation. The resulting tool wear and surface roughness after high speed machining were then analysed using ANOVA to determine the cutting parameters which is most affecting the surface roughness.

Numerical Investigation on Effect of Rounded Cutting-Edge Radius and Machining Parameters in End Milling of AISI H13 Tool Steel

Rounded cutting-edge radius is commonly applied to finish and semi-finish cutting, precision machining and micro-machining. The optimum effect is closely related to the work and tool material as well as machining parameters. However, for numerous cutting process, the optimal radius of rounded cutting-edge radius and machining parameters applied in the AISI H13 of end-milling is yet unknown Therefore, in improving tool life and cutting tool performance, a suitable design of cutting edge geometry regarding cutting edge-radius and machining parameters need to be examined and properly selected. In this regard, the paper deals to examine the effect of cutting edge-radius in rounded form and machining parameters of cutting force, cutting temperature and chip formation through the end-milling process of AISI H13 using uncoated cemented carbide cutting tool through finite element simulation of Thirdwave AdvantEdge 7.2 software. The machining parameters applied in the simulation setup were 200 and 240m/min of cutting speed, 0.03 and 0.06mm/tooth of feed-rate and axial depth of cut of 0.1 and 0.2mm while width of cut in radial direction was kept constant at 6.0mm. The cutting geometries includes the cutting-edge radius of 0.03 and 0.05mm and 10° of rake angle. The obtained results revealed that cutting forces and cutting temperature is increase as depth of cut in axial direction and cutting-edge radius increases while increasing value of speed and feed-rate of cutting resulted in decreasing cutting forces but increasing cutting temperature. The maximum cutting temperature is 674.91℃. The value obtained is lesser than the AISI H13 austenitizing temperature, therefore a layer known as white layer is supposedly hard to be created based on the cutting geometry and machining parameters applied.

Critical thrust force and critical feed rate in drilling flax fibre composites: A comparative study of various thrust force models

Past experimental and analytical studies for determination of critical thrust force that contributed toward minimal delamination damage in drilling synthetic fibre reinforced composites have failed to consider the recently developed natural fibre composites. From this point of view, critical thrust force and feed rate in drilling of flax fibre composites were comprehensively investigated. Three different thrust force models that were based on linear elastic fracture mechanics and properties of the composites; namely, Mode I interlaminar fracture toughness, Young modulus and Poisson ratio, were applied in order to determine the critical thrust force values. Empirical relationships between various feed rates and spindle rotational speeds with the drilling thrust force were established via regression analyses. These relationships would aid in predicting the critical feed rate while drilling the aforementioned composites. The results reveal that critical feed rate in between the range of 0.15–0.18 mm/rev was desirable for minimisation of the onset delamination damage on the composite laminates. However, the stiffer crystalline structure of the flax fibres as compared to the synthetic fibres inflicted toward the presence of delamination damage below the critical feed rate and thrust force values.

Manufacture of absorber fins for solar collector using incremental sheet forming

This article sets out to present a new manufacturing process applied to create absorber fins for solar collectors. Using Incremental Sheet Forming, a flexible process that can be performed at a CNC production center, it is possible to make prototypes of absorber fins with collector riser fittings, which also enables the development of new fin designs using different materials in a wide range of thicknesses. This article analyzes parameters of the Two Point Incremental Forming process, with a partial die for solar collector absorber fin manufacturing using a 1mm thick aluminum AA1200-H14 in order to determine the influence of the step down and the tool's rotation speed on the sheet's formability, being thus able to determine the most appropriate combination of these parameters to obtain a process with the greatest quality and productivity. A series of 16 experiments was proposed to manufacture a small absorber fin comparing the rotation speed values of S = 50, 200, 400, and 800rpm, with step down values of Δz=2, 1, 0.5, and 0.2mm. The feed rate value was kept at F=250mm/min, and each experiment was performed until the first crack occurred in the sheet. In this study, it was possible to indicate the feasibility of the process under more efficient parameters for manufacturing absorber fins using the step down of 2mm and the rotation speed of 50rpm.

Struktura geometryczna powierzchni po toczeniu wykończeniowym stali martenzytycznej AISI 630

The surface texture of martensitic AISI 630 steel after the finishing turning is described. The tests were carried out under dry and cooling conditions. Experiments were carried out under variable cutting speeds and feeds and under a constant depth of cut. The Parameter Space Investigation (PSI) method was used that allows research with minimal experience point quantity. It was found that turning with cooling conditions reduce both Ra and Rq values and intensities of cutting speed and feed rate influence as compared out under dry conditions. The use of low feed rate values has a positive effect of the Ra and Rq parameters.

The influence of process parameters on mechanical properties and corrosion behavior of friction stir welded aluminum joints

Aim of the present paper is to analyze if and how the process parameters (namely rotational speed S and feed rate f) affect both the mechanical properties and the corrosion behavior of friction stir welded (FSWed) butt joints made of AA7075 and AA2024 alloys and their combination. Tensile tests were performed orthogonally to the welding direction on specimens having the welding nugget placed in the middle of gage length. Rockwell tests were carried out on each specimen moving from the joint axis until the hardness of the base material was reached. A clear dependence of the Ultimate Tensile Strength (UTS) from the process parameters were observed when the joints are obtained using the same material while the effect is not so evident when two different materials are concerned. In almost all cases, the best conditions, in terms of mechanical resistance, were obtained for intermediate values of rotational speed and feed rate. Further tests were performed for evaluating the corrosion behavior and the stress corrosion cracking susceptibility of FSWed joints. In particular, local corrosion potential measurements were executed and longtime immersion tests were carried on four points bending specimens loaded up to 80% of the Yield Strength (TYS), in 35 g/L sodium chloride solution. The same tests were replicated on unloaded specimens. The potential trends are always well defined and much higher for the AA2024 alloy, since it is more noble than the AA7075 alloy. Mixed welding allows to identify the AA7075 alloy as an anode part, having a lower copper concentration and a high concentration of zinc. A correlation of some corrosion behaviors to the mechanical characteristics was evidenced, in particular for the AA2024 alloy.

Optimization of process parameters for micro milling of Ti-6Al-4V alloy using Taguchi-based gray relational analysis

In this study, the effects of the cutting parameters on the surface quality and burr width were investigated in the micro milling of Ti-6Al-4V alloy. Spindle speed, feed per tooth and depth of cut are selected as the control factors. Taguchi-based gray relational analysis was used in the optimization of the cutting parameters for minimal burr width (for up and down milling operations) and surface roughness (Ra). The contribution percentages of the control factors were determined by using analysis of variance (ANOVA). According to the obtained results, it was determined that the feed rate value for the best surface quality was 0.25 μm/tooth. At lower feed rate values, ploughing takes place and the surface quality deteriorates. On the other hand, it was found that it is more appropriate to use values ap of 0.1 mm and n of 10,000 rev/min to produce minimal Ra. The burr width on the down milling side is higher than that on the up milling side. A lower feed rate and greater depth of cut lead to an increase in burr width. In addition, higher spindle speeds increased the burr width due to rapid tool wear.