Papers by Keyword: Cutting Speed

Abstract: This study presents a novel approach to optimizing energy consumption in rock destruction by integrating advanced design parameters of cutting elements. A hybrid experimental-computational model was developed to evaluate the specific energy of destruction () across granite, limestone, and sandstone. Key findings include energy savings of 15% in granite, 12.5% in limestone, and 13.7% in sandstone, achieved by optimizing the angle of attack – 30º, edge curvature – 0.5 mm, and applying wear-resistant DLC coatings 2500 HV. Laboratory tests, field experiments, and finite element simulations validated the model's accuracy within ±6%. The study identifies critical parameter interactions, such as angle of attack and coating hardness, reducing shear stresses and wear losses. These advancements lower operational costs by approximately $50,000 annually per excavator and extend tool life. Limitations include the limited range of rock types tested and slight simulation overestimations in abrasive sandstone. Future research should explore adaptive cutting element designs with real-time parameter adjustments using sensor-based systems and machine learning. The findings offer practical recommendations for implementing optimized tools in mining and construction, enhancing efficiency and cost-effectiveness. This work bridges theoretical insights and industrial applications, providing a scalable framework for energy-efficient rock destruction.

Abstract: In machining process, surface roughness and material removal rate have a vital importance since they affect mass production, consumption of energy, force, and tool life and product quality. In this study, Taguchi-Grey Relation Method (TGRM) is applied to AISI 1040 mild steels in the hardened form when machined with ceramic inserts using response surface methodology for multi-objective optimization. Grey-Relation Method and Pareto chart reveal that feed rate, depth of cut, speed besides square effect of speed/feed rate are effective parameters on the response. Among all eighteen experiments, trial twelfth provides the best multi-performance characteristics while the first experiment shows the worst performance. Optimal levels are determined at higher speed, higher feed rate associated with higher depth of cut. It is concluded that quadratic regression model and reduced quadratic regression model are developed. The correlation coefficients range from 98.3% to 96.89%, respectively. As a result, TGRM has an efficient to provide a good modelling in combination of surface roughness and metal removal rate.

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 paper presents a mathematical model for calculating cutting forces during the machining of 16MnCr5 steel using the Sandvik CNMG 120408 16P25T tool. The modeling process involved the use of a test rig constructed based on the 16Д25 machine, which enabled the measurement of real values of spindle speed, longitudinal feed, cutting depth, and cutting forces. The results transmitted to a computer through the LTR-EU-8 workstation, equipped with galvanic isolated LTR modules and a synchronization interface. Based on the experimental results, the theoretical model demonstrated a deviation from actual measurements of no more than 4.72%. The study provides evidence that the cutting force calculations commonly presented by leading tool manufacturers are inherently overestimated. he difference in cutting forces can be 9%.

Abstract: With the enhancement in science and technology, necessity of complex shapes in manufacturing industries becomes essential for more versatile applications. These lead to demand for light weight and durable materials for applications in aerospace, defence, automotive, as well as sports and thermal management. Due to its high-tech structural, functional applications like defence, automobile, aerospace, thermal sensitive materials. Al-Matrix composites are considered as one of those classes of advanced engineering materials. In the present study, Al-RHA (Rice Husk Ash) composites are prepared by powder metallurgy route using 10% and 15% RHA by weight as reinforcement. Presence of abrasive particles leads to difficulty of conventional machining on Al-RHA composites hence non-conventional machining WEDM (Wire-Electric Discharge Machining) has been investigated. Suitable machining parameters for composites using wire EDM have been tried to get maximum material removal rate and speed. Optimizations of experimental parameters have been studied using Taguchi and Anova to standardize the process parameters for machining. Prime process parameters like servo-voltage, pulse-on time and pulse-off-time have been taken into consideration to study cutting quality of Al-RHA Metal matrix Composite using cutting speed as response parameters while effect of RHA weight fraction addition is also considered for evaluation to understand its influence on affecting the response.

Abstract: In today’s industrial scenario, the requisite for elevated efficiency, better economic viability and higher quality asks for immense improvements in the cutting process stability. Such machining at higher cutting speeds and cutting depths causes an immense amount of heat generation at the work tool interface. The industry makes utilization of cooling techniques to contravene these ill-effects. These techniques make utilization of chemical coolants which are non-biodegradable in nature and consumed in immense quantities. In this study the role of minimum quantity lubrication (MQL) or green machining was experimentally evaluated when utilizing nanoparticle enriched coolants. The effect on the wear and roughness values while turning commercially pure Titanium (Grade 3) was analyzed. Experimentation was performed in two phases. In the first phase, the comparison in dry, flood and MQL process was made. The experimental design was composed factorially and 16 experiments were performed. Analysis was carried out utilizing ANOVA and the results were compared. In the second phase, a graphical cognation was established between the coolant application rate with both surface roughness and flank wear values. It was concluded that the nanoparticle enriched coolant i.e. the “eco nanomist”technique was more efficacious when machining the biocompatible Titanium grade 3.

Abstract: The processing of materials with a hardness greater than 55 HRC has always required the use of unconventional or grinding methods in order to obtain the quality and precision required by the technical conditions. For these reasons, the researches of the last decades have developed an unconventional method of processing, with great precision and precision, by assisting the classic processing techniques, with forced, unamortized, low amplitude ultrasonic vibrations. The present paper presents the results of some researches regarding the processing of extradural materials, by the assisted realization of the non-cushioned, low amplitude ultrasonic vibrations. It is demonstrated that this method of processing can obtain very fine surfaces, sometimes being able to replace the grinding, with much lower costs, in terms of energy consumption and tool wear.

Abstract: This article studies dry hobbing of external cylindrical wheels by worm wheel hobs and reasons why some gear manufactures use hobbing without cutting fluids. Cutting fluids reduce frictional wear, provides temperature cooling of the tool or workpiece and helps flush away the chips from the cutting zone. But uneven cooling and different cutting conditions on the engaging and disengaging sides of a gear mesh provoke intensive wear of the teeth of the worm wheel hob, thus decreasing the life of worm hobs and increasing both the consumption of cutting tools and expenses for them. In this context, it becomes rather difficult to achieve efficiency and stability for the hobbing process. In the recent times, the cost of coolant disposal has been raised; in some cases, it accounts for 15-20% in terms of shop costs. Research was carried out under the following experimental conditions: a hobbing machine equipped with an automation system of high efficiency and with basic units of high static and dynamic stiffness; a high-accuracy worm hob from powdered metal wear-resistant high-speed steel of grade Р6М5К5; a workholding device with an elastic bush, and various cutting modes. Recommendations are given on using the multi-cycle hob-shifting strategy rather than the strategy of single-cycle shifting; and advantages gained by this technique are observed. Best cutting conditions and precision attained by dry gear-hobbing are described.

Abstract: In order to increase the cutting and breaking capacity of abrasive water jet machining (AWJM), abrasive particles are usually added to water. The AWJM technology is generally used for harder and heavier machinable materials like thick sheets, composite materials with metal and ceramic properties and others within these categories to just cite a few. The contribution is mainly focused on the analysis of the surface properties of the steel S235 after the cutting process, and this depending on the cutting speed of the water jet. Three different cutting speeds were used for the analysis because this cutting parameter significantly affects the resulting quality of the machined surface. A contact profile method was used to analyze surface roughness. The observed surface roughness parameters were the Ra, Rt and Rz respectively. The above-mentioned surface roughness parameters were measured in three positions, i.e.: at the inlet, middle and exit positions of the water jet with respect to the machined material.

Abstract: Machining parameters is a main aspect in performing turning operations using lathe machines. Cutting parameters such as cutting speed, feed rate and depth of cut gives big influence on the dynamic behavior of the machining system. In machining parts, surface quality and tool wear are the most crucial customer requirements. This is because the major indication of surface quality on machined part is the surface roughness and the value of tool wear. Hence, to improve the surface roughness and minimize the forming of tool wear, the optimum feed rate and cutting speed will be determined. The input parameter such as cutting speed, feed rate and depth of cut always influence the tool wear, surface roughness, cutting force, cutting temperature, tool life and dimensional accuracy. The D2 steel was being investigated from the perspective of the effect of cutting speed and feed rate on its surface roughness and tool wear. The results show that cutting speed is the main parameter which affects the surface roughness where the most optimum parameter would be at cutting speed of 173, 231 and 288 m/min with feed rate of 0.15 mm/rev. The tool wear strongly affected by feed rate where at 0.15 mm/rev the tool wear value is the lowest. The combination of high cutting speed and low feed rate was the best parameter to achieve smooth surface roughness.