Papers by Keyword: Cutting Parameters

Abstract: The aim of this study were to evaluate the performance of PVD (TiAlN+TiN) and CVD (TiCN+Al₂O₃+TiN) coated inserts in end milling of EN–31 hardened die steel of 43±1 HRC during dry and MQL (Minimum quantity lubrication) machining. The experiments were conducted at a fixed feed rate, depth of cut and varying cutting speed to measure the effect of cutting speed on cutting force and tool wear of CVD and PVD-coated inserts. The performance of CVD and PVD-coated inserts under dry and MQL condition by measuring the tool wear and cutting force were compared. During cutting operation, it was noticed that PVD inserts provide less cutting force and tool wear as compared to the CVD inserts under both dry as well as the MQL condition because PVD inserts have a thin insert coating and CVD inserts have a thick insert coating, but PVD inserts experience catastrophic failure during cutting operation whereas CVD inserts have a capability for continuous machining under different machining. Tool wear has measured by SEM analysis. The result shows that MQL machining provides the optimum results as compared to the dry condition. MQL machining has the ability to work under high cutting speed. As the cutting speed increases the performance of dry machining was decreased, but in MQL machining, the performance of the inserts was increased with increases of cutting speed. MQL machining generates less cutting force on the cutting zone and reduces the tool wear which further increase the tool life.

Abstract: In order to study the complex groove inserts in the cutting process caused by temperature variation of cutting,Using multi factor cutting method and combined with finite element simulation technology, from cutting parameters and chip-breaking groove two aspects influence on cutting temperature and cutting force cutting tests were carried out and experimental study on the complex groove turning insert edge chamfering, rounded cutting edge radius on cutting temperature effects. Also tested the effects of temperature on the chip shape cutting and breaking, and analyzed the temperature on the Influence law of cutting tool wear, thus providing a theoretical basis for tool wear.

Abstract: Manufacturing industries have consumed 30% of the total world energy. The main energy source used in those manufacturing industries is the electricity generated from fossil fuels such as oil, gas, and coal as a result in causing the environmental and economic issues. This paper presents an experimental study in order to get the minimum energy consumption during turning of aluminum 6010 with the conventional machine tool under dry cutting condition by optimizing the cutting parameters to contribute to those issues. An analysis of variance (ANOVA) was employed to analyze the effects and contribution of depth of cut, feed, and cutting speed on the response variable, specific cutting energy. The result of this experiment showed that the feed was the most significant factor for minimizing energy consumption followed by the cutting speed and the depth of cut. The minimum energy consumption was obtained when the highest level of cutting parameters have been used.

Abstract: Fabrication of microchannels on titanium alloy with micro-milling is a tough challenge due to the difficultly to remove the burrs formed in machining process. A novel method to gelatinize workpiece surface to control the generation of burr as well as the optimization of cutting parameters are investigated in this paper. Differences existed between the process of micro-milling and that of traditional milling can be accounted for size effect. Influences of feed per tooth, depth of cut and spindle speed on the formation of burr were taken into consideration respectively by single factor method. The topographies of the machined surface with micro-milling were observed and measured by optical microscope. Results showed that the dimensions of burrs increased with the rise of depth of cut. However, it decreased initially, then increased later with the augment of feed per tooth. Sacrifice layer with PMMA was coated and gelatinized on the workpiece surface, which could restrain the plastic deformation of materials during titanium alloy micro-milling. The experimental results presented that the dimensions of burr could reduce greatly by the proposed PMMA coating method compared to materials without coating.

Abstract: The form, shape and dimensions of the scaled down winglet model become small and thin bringing complexity to manufacturing. The trailing edge tapers to a thickness varying from 0.065mm to 0.099mm along its length. The mounting portion of the winglet is provided with a close tolerance having a slot gap of 5mm and a depth of 35 mm with an angle. Additionally, wind tunnel models require good surface finish on the aerodynamic surfaces and this involves adopting a manufacturing strategy with a control over on the metal cutting parameters to be implemented on a three axes CNC machining centre. The winglet surface is divided into segments in order to handle the cutting forces on the varying aerodynamic cross section. Various metal cutting parameters such as tool path, cutter diameter, feed rate, depth of cut, spindle speed, etc., are evaluated by monitoring segments where the metal cutting is carried out [1] and flow of chips observed. Fixtures and lugs are planned effectively to accommodate the machining of the angular slot in a three axes machining centre itself. Routing of operations to handle the varying thin sections and realisation of the close tolerance slot has enabled a reliable manufacturing approach in an economical way.

Abstract: Recently, the need arises for new machining inprocess techniques to monitor and/or control machining systems. Due to the introduction of digital thermal noncontact cameras, it becomes possible to assess the chip temperature hence, to evaluate the possible relation between edge performance and variation within such temperature. A noncontact infrared thermal camera is mounted on a turning lathe carriage to record the cutting temperatures as cutting speed and feed vary using both coated and uncoated carbide inserts. Temperatures gradient, along with the relevant SEM micrographs, are analyzed for possible correlation with both regular and irregular cutting edge deformation. While cutting speed proved not to be an influential parameter on the depicted temperatures, feed increase tends to lower cutting temperatures. Generally, it is observed that lower heat and temperatures are generated when coated inserts are employed. It is found that cutting temperatures are gradually increased as edge wear and deformation develop.

Abstract: The cutting force is the main important factor contributing the machined work piece surface and in determining the acceptable cutting parameters for high productivity in metal cutting industries. The prediction of cutting force coefficients of materials were calculated from the average cutting force model contributing to the constants of cutting force coefficients. In this study, experimental investigation is conducted to determine the cutting force coefficients in the average cutting force model, by identifying cutting force coefficients with different lubrication conditions such as dry, flood and minimal lubrication conditions and cutting speeds. A series of slot milling experiments are measured the milling forces by fixing the spindle speeds and radial/axial depths of cutting and linearly varying the feed per tooth. Using linearly fitting the experimental data, the tangential and radial milling force coefficients are then computed. The achieved results showed that the changing of spindle speed and different lubrication conditions affecting the milling force coefficient.

Abstract: The paper presents the influence of various cutting regimes on the surface roughness, when a hardened bearing steel has been machined using both ceramic and PCBN cutting tools. There were used different cutting conditions varying cutting speed, feed rate and depth of cut in order to determine the influence of each cutting parameter on the surface finish.

Abstract: The machining of hard turning is performed on hardened steel in the range of 45 to 68 Rockwell hardness using a variety of tool materials such as Polycrystalline cubic boron nitride (PCBN) , Polycrystalline diamond (PCD) and Cubic boron nitride (CBN). It is an alternative to conventional grinding process is a flexible and effective machining process for hardened metals and hence broadly used in various applications such as dies, moulds, tools, gears, cams, shafts, axles, bearings and forgings. Although the process is performed within small depth of cut and feed rates, estimates to reduce machining time as high as 60 % in hard turning. This paper discusses the importance of hard turning of AISI D2 steel. In this study, Experimental investigations are carried out on conventional lathe using prefixed the cutting conditions. The responses studied in the investigation are cutting forces (F_a, F_t and F_z). The cutting parameters considered for the investigation are cutting speed, feed and depth of cut. The influence of machining parameters on response is studied and presented in detail.

Abstract: Shape memory alloys (SMAs) are now widely used in many industrial and engineering applications e.g. in aircrafts, space vehicles, robotics and actuators. However the available literature reveals that little or no work is published on the machinability of these alloys. In this paper, the effect of the main cutting parameters namely: cutting speed, depth of cut and feed rate on the surface quality of the machined surface of the Cu-Zn-Al shape memory alloy both in the cast and after direct extrusion using a CNC milling is investigated. The cutting speed was varied from 750 to 2000 rpm , the depth of cut was varied from 1 to 4 mm and the feed rate was varied from 100 to 250 mm/min. Furthermore, the general microstructure, the mechanical behavior and hardness of the Cu-Zn-Al shape memory alloy both in the cast and after direct extrusion are determined and discussed. It was found that the best achieved surface quality in this SMA, machined within the different investigated cutting conditions is 0.13 microns at cutting speed of 750 rpm, 1 mm depth of cut and 150 mm/min. feed rate, which is better than the surface quality achieved in other materials at the same cutting conditions.