Papers by Keyword: Chips

Abstract: In this study, Taguchi-L18 design is applied to cut AISI 304 stainless steels based on surface roughness under the effects of main control factors through un-coated carbide (K10 grade) and TiAlN coated carbide. The orthogonal array and analysis of variance are utilized to examine the performance characteristic when turning steel bars. A linear regression analysis is carried out to find out the relationship between input parameters and output. In addition, the chips are collected by both cutting inserts to see the morphology. The experimental results indicated that optimal levels were determined at 190 m/min speed, 0.076 m/rev. feed rate, 1.4 mm depth of cut when used TiAlN coating insert for surface roughness. Pareto chart and analysis of variance results revealed that feed rate was dominant, followed by coated tool and cutting speed in analyzing the surface roughness, but the coating was more effective than that of the speed. Further, it was concluded that correlation coefficients were around 93.8% for output. Confirmation tests were provided by Taguchi method and regression analysis. Moreover, the chips collected by TiAlN carbide inserts showed long narrow chips, leading to lower surface roughness because of obtaining the lowest feed rate/moderate speed and insert hardness in addition to providing the larger chip radius and chip length.

Abstract: The main purpose of the research is to study the floating chips produced during mechanical processing. Chips derived from aluminium material cause several difficulties in mechanical processing. Research shows that floating chips clog filters in chip conveyors, resulting in significant downtime in production processes. In this article, cause-effect research has been carried out to find approaches to solving this problem.

Abstract: It is noted that the technology for the manufacture of ferrosilicon-magnesium modifiers (crystallization into an ingot in a mold or into a chip on a water-cooled drum) forms their quantitative and qualitative structural differences: the size and distribution of phases, the scatter of the content of elements, etc. The fundamental differences are shown and the features of the distribution of silicon as a base element in ingot and chip modifiers are described. It was found that in ingot modifiers the vast majority of silicon-containing phases are ξ(FeSi) and ζ' (FeSi₂), and with a significantly lower content of pure silicon particles and phases, these are α₁(Fe₃Si) and α₂(Fe₂Si). The picture of the phase structure of the modifier chip has been determined. In it, the 1st mode corresponds to the presence of a set of phases α₁(Fe3Si) and α₂(Fe2Si), and the 2nd mode, as well as in the ingot modifiers ξ (FeSi) and ζ'(FeSi2), but is shifted to the lower boundary of the region their existence. Particles of pure silicon are completely absent in the chip modifier.

Abstract: The paper shows that in the conditions of a deficit of high-quality metal charge in steels melting production, the effective use of waste from abrasive grinding in the composition of the metal charge is a promising method for reducing the cost of steel. The most rational solution for the disposal of metallurgical wastes may be the agglomeration of fine-grained and fine-dispersed materials using briquetting technology widely used in many countries around the world to produce multi-purpose briquettes.

Abstract: The paper presents the method of a microscopic study of ceramic chips which can be useful in the analysis of physical phenomena regarding machining of ceramic materials. The analyzed chips were obtained on the milling machine tool from the Al2O3 based ceramic material. The measurements were performed using focus-variation technique (FVT). The InfiniteFocus Real3D microscope from Alicona Imaging company was applied. The paper mainly focuses on the methodology of measurements and the application of microscope’s software tools which can be used in the analysis of chips' 3D scans. The conditions of measurement process are discussed on the basis of the results of exemplary measurements of ceramic chips.

Abstract: The energy consumption and machinability index of metallic alloys are very important in determining the economic and environmental value of manufacturing process. Various machinability problems with Nitronic 33 steel alloy have been reported in literature. These problems have been attributed to the work hardening of the material during machining operation and hence greatly influences and contributes to the green house gas emission. In this work, the chip and burr formation during the machining of Nitronic 33 steel alloy was investigated in other to optimize the cutting parameters and provide a knowledge base for machinists when machining austenitic stainless steels. The result shows that although continuous chips were formed throughout the machining tests, an evidence of continuous chip with built-up edges was also observed. This phenomenon tends to initiate the formation of discontinuous chips especially at high pressure coolant flow of 7 and 9.7 MPa. It is concluded that conventional cutting environment at 90 m/min cutting velocity is the optimum process parameter most suitable for machining Nitronic 33 steel alloy. The research outcome will address some of the problems encountered during high speed machining of Nitronic 33 steel alloy and the general understanding of the machinability of this alloy.

Abstract: In this paper some experimental determinations on the temperature during the turning of the pure titanium are done, using different cutting conditions. The results are presented as graphical dependencies and also as a screen capture of the values obtained using an adequate technique for registered the temperature during the turning process. Some pictures of the chips shape was captured and presented in this paper

Abstract: In this paper some experimental determinations on the temperature during the milling process of pure titanium is conducted, using different cutting conditions. The results are presented as graphical dependencies and also as a screen capture of the values obtained using an adequate technique for temperature of the cutting process. Some pictures of the chips shape captured during milling process of the pure titanium bare are presented.

Abstract: In order to improve the quality of ADC12 alloy billets prepared by Chips Solid Pressing (CSP) process, the effects of pressing temperature, pressure and packing time on the density of ADC12 alloy billets were investigated by using the orthogonal array and multiple nonlinear regression analysis. The results indicated that the pressing temperature has the greatest effect on the density of the billets, and it is followed by pressing pressure and packing time. The optimized process parameters, including a pressing temperature of 250oC, pressing pressure of 640MPa and packing time of 45 seconds, can be used to obtain the most compact billets of ADC12 alloy prepared by CSP process.

Abstract: Ultrasonic assisted turning (UAT) is a novel manufacturing technology, where high frequency vibrations are imposed on the movement of a cutting tool. A 2D FE transient simulation is developed in DEFORM, where ultrasonic vibrations of frequency 20 kHz and amplitude of 20 μm are provided to the cutting tool in the direction of cutting velocity. The prediction of residual stress distribution is carried out using elasto-plastic finite element simulations. Experimental analysis is carried out in measuring the strain at the cutting tool during CT and UAT along with the chip mechanism and chip microstructure study to validate the residual stress distribution. The ultrasonic vibrations yield a considerable improvement in compressive residual stresses which ultimately benefits in improving fatigue life of titanium alloys.