Workpiece Roughness Research Articles

Parametric optimisation for surface roughness of AISI 4340 steel during turning under near dry machining condition

The objective of this investigation is to find the best feasible machining parameters in order to obtain better surface quality. The turning operation is carried out with TiN coated carbide insert on AISI 4340 steel under near dry machining condition. The machining parameters, namely cutting velocity, feed rate and depth of cut are chosen for the conduct of experiments based on L9(33) orthogonal array. The surface roughness of the machined work piece is measured by using surface roughness tester. A mathematical model representing average surface roughness is developed using nonlinear regression analysis with the help of MINITAB software. The optimum machining conditions for minimum surface roughness are determined through Taguchi's technique and genetic algorithm and verified with confirmation experiments.

Analysis of Surface Finish Improvement during Ultrasonic Assisted Magnetic Abrasive Finishing on Chemically treated Tungsten Substrate

In the era of globalization, the demand of new products with advanced material and process technologies is increasing. Conventional manufacturing techniques are not capable to process the advanced engineering materials with stringent properties. This paper presents a novel approach to finish some advanced engineering materials with stringent properties, which is a challenge for existing conventional machining processes. In this study the positive outcomes of Magnetic Abrasive Finishing (MAF), Chemical-Mechanical Polishing (CMP), and ultrasonic vibrations have been integrated and a novel finishing process Chemo Ultrasonic Assisted Magnetic Abrasive Finishing (CUMAF) has been developed. The machining performance has been enhanced with the process resulting in better surface finish and reduced finishing time. In order to establish the process, an experimental study was done to analyze the influence of five different process variables on surface roughness of workpiece. The response surface methodology and analysis of variance was used to design the experiments and analyze the results respectively. A regression model was also developed and validated, to foresee the process response. Optimization of the model was carried out at the end to obtain the best performance.

Cutting Performance of Fiber Laser Textured Tools in Face Milling of Titanium Alloys

Textured self-lubricating tools were fabricated by fiber laser machining. Dry milling of titanium alloys was carried out with these textured tools and conventional one for comparison. The cutting forces, cutting temperature, surface roughness of processed workpiece and tool flank wear were measured. Results show that the textured tools can reduce the cutting forces, cutting temperature and surface roughness of workpiece, as a result, present superior wear-resistance compared to the untextured tool.

Theory analysis of grinding fluid jet and its effect on surface roughness of workpiece

Theory analysis of grinding fluid jet and its effect on surface roughness of workpiece

Experimental investigation of thermal properties of cutting fluid using soluble oil-based TiO2 nanofluid

In this study, soluble oil-based titanium dioxide was employed as a drilling fluid to enhance the performance of drilling process in terms of smoothness. The results of drilling process in the presence of titanium dioxide as an additive were compared with the dry condition and once applying pure drilling fluid. Further, forced convective heat transfer coefficient of the soluble oil-based titanium dioxide nanofluid flowing through a horizontal circular tube was also investigated experimentally under constant wall heat flux boundary condition. To this end, soluble oil-based titanium dioxide nanofluids were prepared at the weight concentrations of 0.3, 0.6 and 1%. To have a proper colloidal stability, gum Arabic (GA) was used as a surfactant with 1:1 weight ratio of GA and titanium dioxide. The results showed that the addition of titanium dioxide nanoparticles to the soluble oil decreased significantly the surface roughness of work-piece as well as the drilling temperature as compared to the pure soluble oil and dry condition. Moreover, as the concentration of titanium dioxide increased, the convective heat transfer coefficient increased significantly, and it was further improved by increasing Reynolds number. Note that increasing the concentration of nanoparticle into the base fluid was more effective than that of improving Reynolds number in the range studied herein.

Effect of burnishing parameters on surface roughness and hardness

Abstract Burnishing is used as the final operation in machining, and brings along advantages such as increase of hardness, resistance against material fatigue and abrasion resistance on the workpiece on which it is applied. Improving the surface roughness of workpiece, improvements on the surface hardness, increase of the abrasion resistance of the material, decreasing depths on the material surface which may cause cracks, etc., directly depend on parameters such as progression, number of passes, press amount and ball diameter used in burnishing operation. For this study, an apparatus was designed which has different heads for a burnishing operation of rotary pieces. The surface of an Al 6061-T6 alloy was subjected to a respective burnishing operation and the effect of the parameters (i. e., pressure force, progression, number of passes and ball diameter) used in the burnishing operation on the surface roughness and surface hardness was determined. In addition, an artificial neural network (ANN) and an adaptive neuro-fuzzy interference system (ANFIS) model are developed for these parameters. Both models provide accurate results that are comparable to the experimental results. However, the ANFIS based model appears more accurate, compared to the ANN based model with respect to the same conditions for the surface roughness and surface hardness.

Large taper mechanism of HS-WEDM

Large taper (≥ ± 5°) high-speed wire electrical discharge machining can be affected by many factors. The positioning error of wire electrode caused by guide wheels and the run-out of guide wheels are particularly important. Moreover, dielectric fluid cannot wrap the wire electrode appropriately and flow into the machining region along with the wire electrode in tilt directions. As a result, the machining accuracy and surface roughness of a large taper-cutting workpiece are worse than those of straight cutting. In order to solve these problems, this paper presents the design and improvement of two types of six-bar linkage large taper-cutting mechanisms that can realize the guide of wire electrode and the tracking spray of dielectric fluid along with the incline of the wire electrode. The first type causes angular error but no wear, whereas the second one causes wear but no angular error. The former is applied to process experiments. The experimental results show that, compared with traditional mechanisms, this new approach decreases the roundness error of the workpiece from 80 to 40 μm and the surface roughness from 4.059 to 3.495 μm under the same processing parameters. In terms of multi cutting (skim cutting), the new mechanism reduces the roundness error of taper cutting (taper ±20°, thickness 40 mm) to 25 μm and the surface roughness to 1.670 μm. An idea of intelligent servo traverse guider based on this mechanism is also proposed in this study.

Turning of aluminum metal matrix composites: influence of the reinforcement and the cutting condition on the surface layer of the workpiece

Aluminum metal matrix composites (Al-MMCs) are difficult to machine. The reinforcement of aluminum using ceramic particles accelerates tool wear. Moreover, demanded machining accuracies or properties of the surface layer are difficult to achieve. In the present study, the effect of silicon carbide reinforcement particles on the surface layer of the workpiece was investigated using multiple cutting conditions for dry turning. Three differently reinforced Al-MMCs regarding the volume percentage (17% and 30%) and the particle size (0.6 µm and 3 µm) and their non-reinforced matrix were considered as the workpiece materials. The reinforcement and the cutting condition affect the results of turning. A greater particle volume percent improves the surface roughness and decreases the tensile stress in the surface. The smaller particle size caused a lower tensile stress in the surface. A general effect of the particle size on the workpiece roughness can not be concluded. The most important cutting parameter for the surface layer of the workpiece is the feed. Greater feeds decrease the tensile stress in the surface, but deteriorate the surface quality.

Multi-objective optimization of circular magnetic abrasive polishing of SUS304 and Cu materials

In this paper, a Multi-objective particle swarm optimization algorithm (MOPSOA) is applied to optimize surface roughness of workpiece after circular magnetic abrasive polishing. The most important parameters of polishing model, namely current, gap between pole and workpiece, spindle speed and polishing time, were considered in this approach. The objective functions of the MOPSOA depend on the quality of surface roughness of polishing materials with both simultaneous surfaces (Ra1, Ra2), which are determined by means of experimental approach with the aid of circular magnetic field. Finally, the effectiveness of the approach is compared between the optimal results with the experimental data. The results show that the new proposed polishing optimization method is more feasible.

Experimental Studies to Validate Computational Fluid Simulation of Coolant Flow Behavior through different Nozzles for Nozzle Effectiveness in Cylindrical Grinding Process to Enhance Workpiece Surface Quality

In the present paper, ANOVA (Analysis of Variance) technique has been adopted. The simulated results of flow behaviour through six different kinds of nozzles were experimentally validated to study the effect of these different types of nozzles as well as other process parameters on the response parameter namely surface roughness of ground workpiece during a cylindrical grinding process and optimized using this technique. The air flow behaviour around the rotating wheel and workpiece was simulated with computational fluid approach in ANSYS CFX. The optimum solution was found coherent with the simulated results. Spline type nozzle followed by convergent-divergent type was found the two best nozzles. Optimized solution also indicated the best parametric setting for the optimum results.

Multi-objective optimization of improved magnetic abrasive finishing of multi-curved surfaces made of SUS202 material

Surface roughness is one of the most significant factors that influence the performance of the loss of power and the wear resistance due to friction in engineering. It is difficult to finish simultaneously multi-curved surfaces by conventional finishing process. Besides, this process has to satisfy the criterion of minimum surface defections, accuracy, and high quality surface finish. This study proposes the improved magnetic abrasive finishing (IMAF) in which a magnetic abrasive finishing process was assisted by ring-magnetic field finishing the multi-curved surfaces made of alloy SUS202 in less processing time. The multi-objective particle swarm optimization (MOPSO) algorithm with the knee point (a better solution) was applied to optimize surface roughness of workpiece. The objective functions of the MOPSO depend on the quality of the surface roughness of finishing materials for both simultaneous surfaces (Ra1, Ra2), which are determined from experimental approach. Finally, the effectiveness of the process is compared between the optimal results and the experimental data.

ANFIS based Model for Surface Roughness Prediction for Hard Turning with Minimal Cutting Fluid Application

Background/Objectives: Nowadays artificial intelligence plays an important role in manufacturing sector. How to utilize that in an effective manner is a key factor of optimization. So identification of optimal modeling tool for effective manufacturing gives an extraordinary output. Methods/Statistical Analysis: This paper develops an Adaptive Neuro Fuzzy Inference System (ANFIS) model with hybrid model to predict the Surface Roughness (SR) of the H13 tool steel work piece of 45 HRC hardness value. The investigation of operation has been done in hard turning using minimal cutting fluid application. Findings: The effect of the different input parameters like cutting force, temperature and vibration has been analyzed. Here the hybrid type of ANFIS model is created with triangular membership function and the observed results indicated that the predicted output surface roughness is almost very close to the actual output obtained in the experimental work.

Performance Evaluation of Vegetable Oil based Cutting Fluid during Hard Turning of AISI 4340 Steel with Minimal Cutting Fluid Application

During modern era of manufacturing hard turning of steel is performed with excessive supply of cutting fluids. Much of the cutting fluids are emulsions of petroleum based oil that can cause severe environmental hazards. Dry machining is a logical substitute as it is trouble free from the environmental issues. On the other hand, under dry condition, surface roughness of work piece and tool life is usually influenced on machining. Under those circumstances, Minimal Cutting Fluid Application (MCFA) can be considered as a feasible alternate. In current research an effort has been taken for exploring the various effects of vegetable oil (soya bean oil) based cutting fluid with minimal application of cutting fluid on hard turning of AISI4340 steel. Accordingly, soya bean oil based emulsion was prepared by adding important additives. A comprehensive experimentation was carried out using Taguchi's design to comprehend the influence of fluid application parameters on cutting force. Research showed promising outcomes through cutting force reduction.

Experimental research on performance of monolayer brazed diamond wheel through a new precise dressing method—plate wheel dressing

The application of monolayer brazed diamond wheels in machining hard–brittle materials is always limited for the high transverse roughness on the ground surface of the workpiece. In the present investigation, a new dressing method, namely plate wheel dressing, was proposed for monolayer brazed diamond wheels in order to reduce the surface roughness of workpiece by micro-removing the over-protruded grits. To evaluate the effect of the dressing method, the grinding performance of the dressed diamond wheel was investigated in grinding SiC ceramics. Results obtained show that the contour of the grits was improved greatly and the quality of the workpiece was pretty good to meet the requirement of precision grinding. The transverse surface roughness Ra value reduced to the minimum value, i.e., 0.086 μm. This plate wheel dressing method can realize the precise dressing of the monolayer brazed diamond wheel.

Effect of Peak Current on the Performance of WEDM

WEDM process is used extensively where the conventional machining process shows their limitations. Wire Electrical Discharge Machining is used to manufacture geometrically intricate shapes with higher accuracy and better surface finish. In the present study, the performance parameters i.e. cutting speed and surface roughness were investigated. The experiments were conducted under the constant cutting parameters of TON, TOFF, WP, WF, WT, SV. In the present study, brass wire having diameter 0.25mm was used as wire electrode. The brass wire was operated on the D3 work piece material having thickness of 20 mm. During the experimentation, it had been found that the cutting speed and surface roughness increases with increase in peak current. Scanning Electron Microscopy (SEM) images revealed the surface roughness of work piece (after machining).

Iterative surface warping to shape craters in micro-EDM simulation

This paper introduces a new method for simulating the micro-EDM process in order to predict both the tool's wear and the workpiece's roughness. The tool and workpiece are defined by NURBS patches whose shapes result from an iterative crater-by-crater deformation technique driven by physical parameters. Through hundreds of thousands of local surface warping, the method is able to compute the global as well as the local shapes of the tool and workpiece. At each step, the warping vector and function are computed so as to be able to generate a spherical crater whose volume is also controlled. While acting very locally to simulate the real physical phenomenon, not only the method can evaluate the tool's wear from the overall final shape at a low resolution level, but it can also estimate the workpiece's roughness from the high resolution level. The simulation method is validated through a comparison with experimental data. Different simulations are presented with an increase in computation accuracy in order to study its influence on the results and their deviation from expected values.

Effect of hybrid texture combining micro-pits and micro-grooves on cutting performance of WC/Co-based tools

Friction at the tool-chip interface may be reduced by introducing a lubricant into the tool-chip interface; the effectiveness of which can be enhanced by surface texturing the tool. Micro-grooves, micro-pits, and hybrid texture combining micro-pits and micro-grooves were fabricated employing laser on the rake face of carbide tools, with a view to facilitating lubricant penetrate and retention; then, solid lubricant (molybdenum disulfide) was applied to fill micro-textures to form micro-pools. In the present study, the effect of hybrid texture on the cutting performance was experimentally investigated using the hybrid-textured tools, single-textured tools, and conventional tools in dry turning pure iron tests on the numerical control lathe. The behavior of these tools was quantified in terms of the cutting forces, cutting temperature, friction coefficient at the tool-chip interface, shear angle, surface roughness of machined workpiece, chip morphology, and tool wear on the rake face. Results confirm enhanced cutting performance of hybrid-textured tools by collaborative complementation as micro-reservoir for constant lubricant replenishment of micro-grooves and micro-pits. It is suggested that the hybrid-textured self-lubricating tool is applicable to a stable dry cutting of pure iron.

Modeling and optimization of tool vibration and surface roughness in boring of steel using RSM, ANN and SVM

In this paper, statistical models were developed to investigate effect of cutting parameters on surface roughness and root mean square of work piece vibration in boring of stainless steel. A mixed level design of experiments was prepared with process variables of nose radius, cutting speed and feed rate. According to design of experiments, eighteen experiments were conducted on AISI 316 stainless steel with PVD coated carbide tools. Surface roughness, tool wear and vibration of work piece were measured in each experiment. A laser Doppler vibrometer was used to measure vibration of work piece in the form of acousto optic emission signals. These signals were processed and transformed in to different frequency zones using a fast Fourier transformer. Analysis of variance was used to identify significant cutting parameters on surface roughness and root mean square of work piece vibration. Predictive models like response surface methodology, artificial neural network and support vector machine were used to predict the surface roughness and root mean square of work piece vibration. Cutting parameters were optimized for minimum surface roughness and root mean square of work piece vibration using a multi response optimization technique.

The Cutting Speed Influences on Tool Wear of ZTA Ceramic Cutting Tools and Surface Roughness of Work Material Stainless Steel 316L during High Speed Machining

The purpose of this research is to find the effects of cutting speed on the performance of the ZTA ceramic cutting tool. Three types of ZTA tools used in this study which are ZTA-MgO(micro), ZTA-MgO(nano) and ZTA-MgO-CeO2. Each of them were fabricated by wet mixing the materials, then dried at 100°C before crushed into powder. The powder was pressed into rhombic shape and sintered at 1600°C at 4 hours soaking time to yield dense body. To study the effect of the cutting speed on fabricated tool, machining was performed on the stainless steel 316L at 1500 to 2000 rpm cutting speed. Surface roughness of workpiece was measured and the tool wears were analysed by using optical microscope and Matlab programming where two types of wear measured i.e. nose wear and crater wear. Result shows that by increasing the cutting speed, the nose wear and crater wear increased due to high abrasion. However, surface roughness decreased due to temperature rise causing easier chip formation leaving a good quality surface although the tool wear is increased.

An investigation into surface roughness of work piece produced by chromium powder suspended dielectric in PMEDM process

In this research article, an investigation of surface roughness (SR) of work surfaces produced by the powder mixed electrical discharge machining of EN-8 steel has been carried out. Response surface methodology has been used to plan and analyse the experiments. Average current, duty cycle, electrode angle and concentration of chromium powder added into the dielectric fluid were selected as process parameters. Experiments have been performed on a newly designed experimental set-up developed in the laboratory. An empirical model has been developed for surface roughness. In addition, the recommended model has been verified by conducting confirmation experiments. [Received 14 May 2015; Revised 14 April 2016; Accepted 8 June 2016]