Papers by Keyword: Cutting Condition

Abstract: Machining processes on hybrid composite materials involve activities such as surface cutting, hole drilling and other cutting processes to achieve final shape and dimension of the composite product. There were several unexpected situations during the process, such as ununiform vibrations due to inconsistent of natural fiber structures and nonideal cutting conditions lead to progressive tool wear and low quality of the cutting surface. In this study, an experimental approach was conducted on the milling process of polyester matrix-based composites reinforced with abaca and glass fibers, produced through the press molding process. The milling process was utilized by a 10 mm diameter 4-flute carbide end mill cutter with a 45-degree helix angle. The study aimed to investigate the influence of cutting conditions (spindle speed, feed, and depth of cut) on vibration during the milling process of abaca-glass fiber composites. Three levels of each cutting parameters were determined based on cutting tool working capabilities, i.e. the spindle speed = 2000, 3000 and 5000 rpm, the feed = 0.004, 0.007 and 0.10 mm/tooth, and depth of cut = 1, 1.5 and 2 mm. The Design of Experiment (DOE) was constructed by Box-Behnken technique of Response Surface Methodology. The down milling process were conducted for all scenario of DOE, and the vibration was measured using a digital accelerometer. The results of the study indicated that vibration increased with the increase of spindle speed, feed, and depth of cut. The results show that the maximum vibration value (0.0206 m/s²) was obtained at a spindle speed of 5000 rpm with a feed of 0.07 mm/tooth and a depth of cut 2 mm. Meanwhile, the minimum vibration value (0.0143 m/s²) was obtained at the spindle speed 2000 rpm, feed 0.04 mm/tooth and depth of cut 1.5 mm.

Abstract: AMS 6260 alloy is a nickel-chromium-molybdenum steel containing Ni, Cr, Mo, with Fe as the main component, and is one of AMS (aerospace materials specifications) in the United States. This material has high hardenability and high toughness. For this reason, it is used as a material for parts that require high toughness, such as gears in aircraft engines. However, while AMS 6260 alloy after heat-treatment has high hardness, it significantly reduced machinability. Therefore, it is extremely difficult to achieve high efficiency and high accuracy in the cutting process of AMS 6260 after heat-treatment. In this paper, the experimental milling of the hardened AMS 6260 alloy after heat-treatment is conducted under some cutting conditions using a coated cemented carbide radius end mill, and the effect of cutting conditions on the flank wear and surface roughness is investigated. As a result, optimal cutting conditions on the tool wear and surface roughness were clarified.

Abstract: Bronze based alloys have come to be used as bearing materials, and require low frictional properties. The present study describes the effects of surface finish machining history on the on tribological properties of sulfide-containing bronze sintered onto a steel disc. The sulfide phase consisted of copper, iron and sulfur, and acted as a solid lubricant. The relative density of the specimen was 90 % and the microstructure showed that the micro-sized sulfide dispersed into the bronze matrix and was accompanied by pores. Various processes, including cutting, burnishing, polishing were, applied to finish the surface. It was found that the area fraction of the sulfide phase depended on the cutting conditions. A further increase in the area fraction was achieved using roller burnishing after the cutting. Tribological properties were evaluated using chromium alloy steel (SUJ2) as the mating surface under dry conditions. The results showed that the friction coefficient depended on the surface finishing process. Therefore, the machining history had an effect on the frictional properties of the sulfide-containing bronze. Optimal cutting conditions for the sulfide containing bronze are also discussed.

Abstract: so-called llightweights materials (aluminum, magnesium, titanium) and their alloys due to multiple applications in various leading industries (aeronautics, automotive, electrical) always stayed in researchers attention both in order to improve their mechanical characteristics and to optimize technologies for cutting processing them. This paper is part of these concerns by trying to find answers to some questions about high-speed drilling of electrolytic aluminum parts and has as targets of the investigation the following: the material machinability, the working parameters optimization, the tool used in drilling and the quality obtained after machining.

Abstract: Recently, cutting has replaced grinding in the finish processing of hardened steel. However, tool damage is a major problem in high-efficiency operations that use high-speed cutting and high feed rate conditions instead of the present cutting conditions. Therefore, the examination of a new cutting technique that can realize high-efficiency cutting is desired. In this study, the effects and efficiency of driven rotary cutting are investigated in the finish turning of carburized hardened steel. Based on the results, flaking occurs at the cutting edge at a short cutting length of 0.2 km using single-point turning. On the other hand, even if the cutting length amounts to 1.5 km, the tool wear width without flaking is small in the case of a driven rotary tool. Additionally, the tool wear is uniformly distributed along the circumference of the cutting edge. Furthermore, based on an examination of high-efficiency processing by increasing the feed rate, it is clarified that a feed rate of 0.3 mm/rev is the optimum condition from the viewpoint of wear resistance and surface roughness. Additionally, even if the cutting length amounts to 5.0 km for this condition, the flank wear width is as small as 0.04 mm, and the tool wear progresses gradually.

Abstract: This paper describes an influence of the cutting condition on the tool performance and the hole shape accuracy in a deep-hole machining of stainless steel with small-diameter drill. The drilling tests were carried out by changing the feed, tool diameter and drill length in order to investigate the appropriate cutting conditions for drilling the holes with deep depth. The results indicate that the increase of the thrust force leads to the buckling of the drill and the work hardening of the workpiece causes the tool failure.

Abstract: The effects of cutting conditions on the surface roughness in a micro-end-milling process of a mold material are described in this paper. Micro-end-milling operations were performed under different cutting conditions such as feed rate and depth of cut, in order to investigate the factors that had the greatest influence on the finished surface during micro-end-milling. It was revealed that the surface roughness begins to deteriorate when the radial depth of the cut exceeds the tool radius. In addition, it was found that this phenomenon is peculiar to micro-end-milling processes.

Abstract: This paper presents the experimental and analytical results of the effect that the amount of cutting fluid has on the surface finish of turned parts. The experiments were planned using Taguchi’s orthogonal array methodology. A three-level, four-parameter orthogonal array (L₈₁) was selected for designing the experiments. The selected four input parameters are cutting speed, feed rate, depth of cut, and amount of cutting fluid. Mild steel AISI 1030 was chosen as the work material. A total of 81 experimental runs were conducted, and the surface roughness parameter arithmetic average was measured offline using a surface finish analyzer. Subsequently, the results were analyzed applying three methods—traditional analysis, Pareto ANOVA, and the Taguchi method. The results indicate that the amount of cutting fluid has a negligible effect on surface finish. However, the interaction between the two major contributors—cutting speed and feed rate—is influenced noticeably by the amount of cutting fluid.

Abstract: Stops to exchange cutting tool, to set up again the tool in a turning operation with CNC or to measure the workpiece dimensions have direct influence on production. The premature removal of the cutting tool results in high cost of machining, since the parcel relating to the cost of the cutting tool increases. On the other hand the late exchange of cutting tool also increases the cost of production because getting parts out of the preset tolerances may require rework for its use, when it does not cause bigger problems such as breaking of cutting tools or the loss of the part. Therefore, the right time to exchange the tool should be well defined when wanted to minimize production costs. When the flank wear is the limiting tool life, the time predetermination that a cutting tool must be used for the machining occurs within the limits of tolerance can be done without difficulty. This paper aims to show how the life of the cutting tool can be calculated taking into account the cutting parameters (cutting speed, feed and depth of cut), workpiece material, power of the machine, the dimensional tolerance of the part, the finishing surface, the geometry of the cutting tool and operating conditions of the machine tool, once known the parameters of Taylor algebraic structure. These parameters were raised for the ABNT 1038 steel machined with cutting tools of hard metal.