Papers by Keyword: Feed Rate

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: Aircraft is still dominated by aluminum alloys despite the growth of composites and other lightweight materials due to their fatigue crack resistance, superior damage tolerance, and mature production methods. Assembly process of the aircraft's structures, must be involved for rivets and bolts, required a precise dimension compliance into the aviation guideline. Poor hole quality is one of the major challenges might cause cracks in the aircraft structure and reduce their reliability thus, manufacturing costs are directly affected by this rejection of parts at the assembly stage. The aim of this paper is to study on feed rate, towards surface roughness and Built Up Edges (BUE), and drilling of aluminium alloys used in aircraft component. An experimental approach was used to determine the most efficient feed rate for drilling operations. Observations were made on the BUE formation and roughness of the surface after each drill had completed up to 30 holes in order to meet the requirements of machined parts. From the experiment's findings, it was observed that the BUE formation and surface roughness both marginally changed as feed rates were varied. This experiment's most efficient feed rate was 0.15 m/min, and met the experiment's goal of determining the most efficient drilling feed rate. In conclusion, as feed rate increased, Ra (surface roughness) increased as well, while BUE decreased. While, Ra was set to a high feed rate, its value increased marginally. Drilling on aluminum alloy T6-6061 was accomplished at an efficient feed rate, resulting in improved product quality and reduced tool and workpiece damage.

Abstract: Composite with woven ramie as reinforcement is a combination of woven from hemp plant fibers with resin adhesive (matrix) which each has different characteristics, which with the combination will produce a new material with better properties. The purpose of this study is to determine the magnitude of the influence of federate variations on the tensile strength of open holes in drilling, with the test method carried out with reference to ASTM D 5766/D 5766M-02 (Standard Test Method for Open Hole Tensile Strength of Polymer Matrix Composite Laminates). The tensile test speed used is 5 mm/minute. The data taken is the maximum tensile strength when the specimen breaks. The results of this study indicate that the change in feed rate affects the tensile strength of the ramie composite. The greater the feed rate used is in grading the ramie fiber composite, the smaller the composite tensile stress value becomes. In this study, the highest tensile strength is obtained from composites with a feed rate of 0.05 mm/rev and the lowest at a feed rate of 0.15 mm/rev. The change in spindle speed also affects the magnitude of the tensile strength in the ramie composite. As with the feed rate speed, the greater the spindle speed used to grind the composite, the lower the tensile strength of the composite. In this study, the maximum tensile strength value tends to be obtained by a composite with a spindle speed of 88 rpm and the lowest at a spindle speed of 1500 rpm. This study uses the type of chisel "brad and spur" with three kinds of diameter variations. The larger the diameter of the drill chisel used, the smaller the tensile strength of the composite obtained.

Abstract: Incremental Sheet Forming (ISF) is emerging as one of the popular dieless forming processes for the small-sized batch production of sheet metal components. However, the parts formed by the ISF process suffer from poor surface finish, geometric inaccuracy, and non-uniform thinning, which leads to poor part characteristics. This paper deals with the influence of single point continuous local forming process parameters on the surface roughness of the product. Design of trials used for research planning and analysis and interpretation of results. The results indicate that the tool diameter (D), vertical step-down size (Δz), and sheet thickness (t) have significant effects on the produced profile accuracy, while the feed rate (f) is not significant. As a general rule, thin sheets with greater tool diameters yielded the best surface quality. The results also show that controlling all surface quality features is complex because of the contradicting effects of, and interactions between, a number of the process parameters.

Abstract: Metal cutting is the way of processing the workpiece with tool having sharp cutting edges of different materials generating chips of different shapes and sizes. In present era of industry 4.0, metal machining should not be unrated during processing of hard grades metals and superalloys where large amount of cutting forces are generated. Also, the measurement of cutting forces provides the basic of economical machining and hence accurate evaluation in experimental and analytical manner has great importance. The traditional models of metal cutting have disagreement with experimental results due to missing of important mechanics terms. With the development of digital technology, the errors in calculation of cutting force have also been shortened due to consideration of terms absent in conventional models. In present investigation, the cutting forces have been evaluated experimentally using dynamometer and analytically with Astakhov’s methodology during turning of EN-31 steel. The results revealed that 12.9% observations have deviation more than 20%, whereas 16.67 % has zero deviation. Further, the feed rate has more influence on cutting forces as compared to speed and nose radius. In addition, the minimum quantity lubrication (MQL) of vegetable oil has lowered the cutting forces appreciably compared to dry machining.

Abstract: In this paper the potential of the recirculation of the EDM debris particles of the workpiece material into the dielectric fluid to increase the tool feed rate v_f in drilling Electrical Discharge Machining (drilling-EDM) is experimentally investigated. Two-Channel electrodes made of copper (Cu) and brass (CuZn) in the range from 1.0 mm to 2.5 mm were used. The effect of the EDM debris particles in the dielectric fluid was investigated at a discharge current i_e of 25 A, a discharge duration t_e of 50 μs and a duty cycle of 80 % by comparing the EDM pulse characteristics and the feed rate v_f of the EDM process with and without debris particles added to the dielectric fluid (particle concentrations C1 = 2.5 g/l and C0 = 0 g/l, respectively). By the recirculation of EDM debris particles the feed rate could be increased up to 36 % depending on the machining conditions. Furthermore, it was observed that the increase in the feed rate is due to the increase of the percentage of discharge pulses and the decrease of short-circuit pulses as well as a more stable machining process.

Abstract: This study evaluates the impacts of machining parameters on the milling of general-purpose poly (methyl methacrylate) (PMMA) with respect to cutting point temperature, maximum machining temperature, and surface roughness. The machining parameters used in the analysis are spindle speed (rpm), depth of cut (mm), and feed rate (mm/min). The extreme ranges of the machining parameters for the material are obtained from trial experiments. From these experiments, four values of each parameter are adopted. This yields 12 experiments, which are divided into three sets. In the first set of experiments, the depth of cut and feed rate are held constant at 0.2 mm and 25 mm/min, while the spindle speed is varied from 1000 rpm to 4000 rpm. In the second set of experiments, the spindle speed and feed rate are held constant at 1000 rpm and 25 mm/min, respectively, while the depth of cut is varied from 0.2 mm to 1.1 mm. In the last set of experiments, the spindle speed and depth of cut are held constant at 1000 rpm and 0.2 mm, respectively, as the feed rate is varied from 25 mm/min to 100 mm/min. Thermal images are obtained during milling, where the cutting point and maximum machining temperatures are obtained. The milled surfaces are then investigated for surface roughness. The chips are also collected from each experiment and used in conducting chip morphology. From the results, it is observed that to obtain the least temperatures and best surface quality, the least machining parameters should be chosen. These parameters are identified as 1000 rpm, 0.2 mm, and 25 mm/min for the spindle speed, depth of cut, and feed rate, respectively. An increase in spindle speed seems to increase the milling temperatures and surface roughness, which is attributed to the reducing chip thickness. An increase in the depth of cut does not affect the generation of chips, and the thickness is relatively constant. However, an increase in milling feed increases the chip thickness, which increases the surface roughness.

Abstract: Quality of the product is the major concern in manufacturing industries from customers as well as producers point of view. There are number of factors in the product such as surface condition, height, weight, length, width etc., which may be consider for the measurement of the quality. Surface roughness and Metal Removal Rate (MRR) are the two main outcomes on which numerous researchers have applied different approaches for several years to get optimum results. In this study, Taguchi Method is applied for getting optimum parameters settings for Surface roughness and Metal Removal Rate (MRR) in case of turning AlMg3 (AA5754) in CNC Lathe machine, which is an aluminum alloy having diameter 20 mm and length 100 mm. The three parameters i.e. spindle speed, feed rate and depth of cut with 3 levels are taken as the process variables and the working ranges of these parameters for conducting experiments are selected based on Taguchi’s L9 Orthogonal Array (OA) design. To analyze the significant process parameters; main effect plots for data means and for S/N ratio are generated using Minitab statistical software.

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.