Papers by Keyword: Cutting Parameters

Abstract: Machining the components precisely and accurately on consistent basis is a huge challenge in the aerospace industry. Nowadays, manufacturer's demand to machine the components to tighter tolerances. In this paper, a case study of machining aircraft rib components in CNC milling was selected and tighter tolerances were defined. For this, two factors: cutting speed and feed rate was considered with five levels. Thus, 25 different combination of experiments were conducted for design of experiments. Several different statistical tools such as normality test, DOE and ANOVA were used. The study outcome found that feed rate has more significant effect over the machining of aircraft rib components than cutting speed; and there is no significant effect found when interaction of both cutting speed and feed rate were defined. The hypothesis test was performed to determine the optimum cutting parameters for the given condition using full factorial ANOVA test.

Abstract: High speed milling is a newly developed advanced manufacturing technology. Surface integrity is an important object of machined parts. Surface roughness is mostly used to evaluate to the surface integrity. A theoretical surface roughness model for high face milling was established. The influence of cutting parameters on the surface roughness is analyzed. The surface roughness decreases when the cutter radius increases, total number of tooth and rotation angular speed, while it increases with the feeding velocity. The high speed face milling can get a smooth surface and it can replace the grinding with higher efficiency.

Abstract: Hard turning is one of the important operations for hardened steels and it has more benefits than grinding such as cycle time, process flexibility, and better surface finish at significantly better material removal rate and lesser environment issues. Although the machining process is performed with low feed rate and depths of cut, it results lesser machining time as compared with conventional turning. This paper discusses the machining performance tests on the AISI D2 hardened steel to 64 HRC were carried out using chemical vapor deposition ( cvd) coated carbide insert. Experiments are carried out on lathe using the cutting conditions prefixed. The responses studied in the investigation are cutting forces (f_x, f_y, and f_z) and. The cutting parameters considered for the investigation are feed rate, depth of cut and cutting speed. The performance of machining parameters on response is studied and presented in detail. In chip morphology study results different formation and types of chips operating under various cutting conditions.

Abstract: The objective of the paper is to obtain an optimal setting of turning process parameters (cutting speed, depth of cut and feed rate) resulting in an optimal value of the feed force when machining En19 steel with tungsten carbide cutting tool inserts. The effects of the selected turning process parameters on feed force and the subsequent optimal settings of the parameters have been accomplished using Taguchi’s parameter design approach. It was indicated by the results that the selected turning process parameters significantly affect the selected machining characteristic. The percent contributions of parameters as quantified in the S/N ANOVA envisage that the relative power of cutting speed (72.09 %) in controlling variation and mean feed force is significantly higher than that of the depth of cut (22.30 %) and feed rate (05.31 %). The predicted optimum feed force is 98.067 N. The results have been validated by the confirmation experiments.

Abstract: In this paper, we take the CNC milling on as the object of the research and establish an optimized model of cutting parameters by using algorithms based on NSGA-II. Taking the machining time and the surface roughness as target function, and the rotational speed and cutting power as constraint condition, the optimization of a CNC milling case is realized, and is verified by simulation of cutting using CAXA ME and Vericut. The outcome confirms the truth that NSGA-II is a useful technique in the optimization of cutting parameters.

Abstract: The mechanism of surface cracks penetration testing are studied, as well as, the cracks’ width and depth of penetration testing formulas are given in the paper, which provide the basis for TC4 titanium alloy structure's penetration testing. The process of fluorescent penetrating testing is analyzed, and the result that detection experiments of TC4 titanium alloy structure's surface crack indicating the changes in the curvature is larger the structure is easier to produce surface cracks. The reason that the surface cracks of structure of TC4 titanium alloy is theoretical analyzed and experimental studied. In process of machining TC4 titanium, cutting parameters are important factors causing stress concentration, particularly, the larger cutting depth will generate surface cracks.

Abstract: Machining accuracy of thin-walled parts is easily affected by clamping and cutting deformation due to its poor stiffness. In this paper, synchronous optimization method of clamping force and cutting parameters is presented based on GA and FEM. The optimization objective is to minimize the maximum deformation and to improve the machining efficiency. GA is used to optimize cutting parameters and clamping force, and FEM is used to predict the machining deformation of the thin-walled workpiece. Finally, taking a titanium alloy thin-walled part with irregular shape as an example, the optimal clamping force and cutting parameters at every cutting position are obtained to demonstrate the feasibility of the method.

Abstract: Cutting temperature is an important factor for nylon cutting properties. The glass transition temperature is suitable to determine cutting conditions. By applying finite element method to this research, the cutting temperatures variation on workpiece and chip with time under different cutting parameters are calculated. It is proved that cutting temperature on workpiece surface is higher than that on chip and decreases quickly. The cutting parameters have great effects on workpiece cutting temperature. The cutting temperatures increase with cutting parameters increase. In addition, the cutting feed has the most effects on cutting temperature.