Papers by Keyword: Machinability

Abstract: Decreasing the effect of temperature, surface roughness and vibration amplitude during turning process will improve machinability. Mathematical model has been developed to predict responses of the surface roughness, temperature and vibration in relation to machining parameters such as the cutting speed, feed rate, and depth of cut. The Box-Behnken First order and second-order response surface methodology was employed to create a mathematical model, and the adequacy of the model was verified using analysis of variance. The experiments were conducted on aluminium 6061 by cemented carbide. The direct and interaction effect of the machining parameters with responses were analyzed. It was found that the feed rate, cutting speed, and depth of cut played a major role on the responses, such as the surface roughness and temperature when machining mild steel AISI 1018. This analysis helped to select the process parameters to improve machinability, which reduces cost and time of the turning process.

Abstract: The present study was undertaken to investigate the effect of alloying additions and aging parameters (time and temperature) on the hardness and machinability of Al-Si alloys. Hardness, drilling force and moment and number of holes drilled/tool measurements were carried out on specimens prepared from grain refined, Sr modified and heat treated Al-Si alloys. Aging treatments were carried out for the as solution treated (SHT) specimens (after quenching in warm water). The specimens were aged at different conditions; artificial aging was carried out at 180˚C, 200 ˚C and 220˚C for 2 and 5 h. Hardness, drilling force and moment and number of holes drilled/tool as a function of different metallurgical parameters (i.e. %Si content, %Mg content, heat treatment parameters (time and temperature), Cu-intermetallics surface fraction and Fe-intermetallic surface fractions) are analyzed to acquire an understanding of the effects of these variables and their interactions on the hardness and machinability of heat treated Al-Si alloys.

Abstract: The information about machinability of two steel – with calcium additives and without in gundrilling are given. Experimentally determined technological characteristics of calcium steel AC41Cr4 machinability in deep hole drilling with the gun drills of diameter 2.05 mm. The results of measurement fluctuation of average diameters of holes and surface roughness are given. Microphotographs of different forms of chips after gundrilling are presented. Information about steel with calcium additives machinability was described.

Abstract: Haynes-25 alloy (also known as L-605 alloy) is extensively used in the applications of aerospace industry, turbine and furnace parts, power generators and heat exchangers and petroleum refining components due to its excellent properties. However, machining this alloy is more difficult compared to normal steel or even stainless one because of its characteristics of hardness and strength. This paper presents experimental investigation into machining parameters in the turning process of Haynes 25 alloy using uncoated carbide tools. Design of experiment (DOE) has been used for studying the effect of the main turning parameters such as cooling condition, cutting speed and feed rate on the arithmetic average surface roughness (Ra) of Haynes-25 alloy. Tests are designed according to Taguchi’s orthogonal array. Experiments have been performed under dry cutting and conventional wet cooling. Minimum surface roughness was obtained in turning using uncoated tools under wet cooling condition at the cutting speed of 45 m/min and feed rate of 0.12 mm/rev.

Abstract: The present study was undertaken to investigate the effect of alloying additions and aging parameters (time and temperature) on the hardness and machinability of Al-Si alloys. Hardness, drilling force and moment and number of holes drilled/tool measurements were carried out on specimens prepared from grain refined, Sr modified and heat treated Al-Si alloys. Aging treatments were carried out for the as solution treated (SHT) specimens (after quenching in warm water) at different conditions. Hardness, drilling force and moment and number of holes drilled/tool as a function of different metallurgical parameters are analyzed to acquire an understanding of the effects of these variables and their interactions on the hardness and machinability of heat treated Al-Si alloys.

Abstract: The performance of a high speed milling process of hardened tool steel depends on various machining conditions which affect the surface quality achieved on the component, the cutting force involved, the mechanism of chip formation, etc. The paper propose is to experimental investigate the cutting forces involved in the machining of a difficult-to-cut material, AISI W1 steel of different hardness states.

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: Many glass fiber reinforced plastic (GFRP) composite components made from primary melt processes require additional machining to meet the requirements of assembly and accurate dimensional tolerances. Importance of woven fabric based glass fibre reinforced composites is widely known in many industrial applications. However, very little is known about machinability of these composites. Cutting force is treated as one of the primary measures for determining the machinability of any material.This paper presents an investigation into the longitudinal turning of woven fabric and epoxy based GFRP composites, using polycrystalline diamond tool, so as to analyze the effect of cutting parameters and insert radius on the cutting force. The force was measured through longitudinal turning, according to the experimental plan, as developed on the basis of Taguchi methodology. The signal to noise ratio and analysis of variance were applied to the experimental data, in order to determine the effect of the process variables on tangential cutting force. Statistical results indicated that the cutting force is significantly influenced (at a 95% confidence level) by feed rate, followed by depth of cut, whereas, cutting speed and insert radius have a smaller influence. The cutting force also increases with the increase in feed rate and depth of cut.

Abstract: Titanium alloy TC25 has been widely used in aircraft industry due to its excellent thermal stability, heat resistance and longer service life. In this paper, cemented carbide tools were applied to carry out orthogonal milling experiments for both titanium alloy TC25 and TC4 with identical cutting conditions. Cutting forces, cutting temperatures and surface roughness were measured to assess the machinability for TC25 and TC4. From the experimental results, the cutting parameters can be optimized to guide efficient machining processing of TC25.

Abstract: This paper will use the Al₂O₃-SiC_w whisker toughening ceramic tool WG300 and Si₃N₄-Al₂O₃ (Sialon) SX9 ceramic tool cutting performance test.Study on different cutting speed, ceramic cutting tool in machining nickel based high-temperature alloy tool life and tool wear mechanism, and analysis of the wear form under different cutting parameters. The test results show that: with the increase of the cutting speed, WG300 and SX9 two kinds of tool durability showed a downward trend, the value of VB is higher than that of Al₂O₃-SiC_w whisker reinforced ceramic cutting tool flank wear of Sialon ceramic cutting tool, but its notch wear value VN is far less than Al₂O₃-SiC_w whisker reinforced ceramic cutting tool,the main failure form of WG300 notch wear, the main failure form of SX9 for the flank wear.