Papers by Keyword: Machining Parameters

Abstract: This study investigates the influence of cutting parameters on tool temperatures and residual stresses during the machining of aerospace alloys Inconel-718, Hastelloy-X, and Ti6Al4V. Experimental turning operations were conducted under predetermined cutting speeds, feed rates, and cutting depths, followed by residual stress measurements using X-ray diffraction (XRD). Maximum tool temperatures were recorded using a thermal camera. Additionally, numerical simulations were performed using DEFORM 3D under identical cutting conditions to validate the experimental findings. The results reveal that Hastelloy-X exhibited the highest residual stresses and cutting tool temperatures, while Ti6Al4V showed the lowest. A close agreement was observed between the experimental and simulation data, highlighting the accuracy of the DEFORM 3D model. This study provides a comprehensive analysis of Hastelloy-X, a material with limited prior research, contributing novel insights into its machining characteristics. The findings will aid in optimizing cutting parameters for improved performance and tool life in aerospace applications.

Abstract: A mechanical work piece created industrially frequently contains more than one machining process. Furthermore, it is a common activity of programmers, who make this selection every time a milling and drilling operation is conducted. Tool wear and borehole quality are two essential challenges for high precision drilling procedures, with Al 356 alloy being employed in experimental planning. Drilling specifications will be assessed in this work to get optimal parameters in minimizing the influence of drilling damage on alloy using a swarm-based optimization model. The drilling parameters are optimized using the Bacterial Foraging Optimization (BFO) method, which includes three control factors: depth, feed rate, and spindle speed. Each parameter is designed in three levels, with multiple performance characteristics such as thrust force, surface roughness, and delamination factor. This investigation was carried out in order to obtain the proper optimization. The feed rate, next to the spindle speed, was discovered to be the essential element inducing lamination in drilling, with this phenomenon occurring in each diameter of the drill bit. The results reveal that the feed rate and drill type are the most important parameters influencing the drilling process, and that employing this strategy can successfully improve drilling process outcomes.

Abstract: In high strength aluminium alloy material turning operation, high material removal and good surface are desirable output characteristics. In this investigation, experiments were conducted according to design of experiments concept with a combination of turning input parameters such as cutting speed, feed rate and depth of cut and also studied the effect of process parameters on multi outputs for machining of Al2024 aluminium alloy. Grey relation analysis was applied to know the robust process parameters. The contribution each parameter was realized with analysis of variance statistical method. The cutting speed is the most influencing parameter with contribution of 62.3% followed by depth of cut with 26.4%, and feed rate with 9.9%.

Abstract: The cutting fluid plays a significant role in minimizing heat generation and chip removal process during the machining of materials, hence improving tool life and surface finish of the workpiece. Many researchers have focused on minimum quantity lubrication (MQL) among the existing methods on the application of the coolant as it reduces the usage of coolant by spurting a mixture of compressed air and cutting fluid in an improved way instead of flood cooling. The MQL method has demonstrated to be appropriate as it fulfills the necessities of ‘green’ machining. Additionally, considering current environmental issues and provisions for safe healthy working conditions at the workplace, it is important to divert machining processes towards an eco-friendly path. Hence, the focus of research has been shifted to MQL using eco-friendly lubricants for green and sustainable manufacturing processes. In this review paper, the effect of different vegetable oil-based biodegradable coolants like castor oil, coconut oil, palm oil, etc. for different machining process parameters like cutting force, cutting temperature, surface finish, tool wear, etc. has been reviewed. It is observed that proper selection of cutting parameters along with lubricant through MQL can provide enhanced machinability to get desired outputs.

Abstract: The development of micro-products in industry, like aviation, medical equipment, electronics, etc, has been increasing lately. The need for scaling down of product has been increasing to make the product simpler and complex. Micro-milling has capabilities in producing complex parts. In this study, mapping and comparing the result of the machining process of Inconel 718 and Aluminum Alloy 1100 was employed. In this experiment, Inconel 718 was used as workpiece material and the result of Aluminum Alloy taken from recent studies. Then, A cutting tool with a diameter 1 mm carbide coating TiAlN was used in this experiment. The machining process was performed with three varieties of spindle speed and feed rate with a constant depth of cut. After the machining is done, the mapping of the result surface roughness of Inconel 718 and AA1100 performed. It was found that Inconel 718 has poor machinability compared with AA 1100. Inconel 718 also has a high manufacturing cost compared to AA 1100 because the cutting tool was easy to wear.

Abstract: Technologists often notice deformations after machining waffle construction of the shell. In that case, size characteristics go beyond tolerance field. Waffle constructions are widely used in aviation and rocket science, because thin-walled constructions allow decreasing mass of products. Results of calculations of standard machining parameters are given in the article. Review of literature sources allow to summarize the main solutions of the problems with deformations. Author has made a conclusion of technological restrictions and field of application of selected approaches.

Abstract: This study investigates the possibility of electrochemical removal of the defective layer formed on the surface of the product after its electrical discharge machining. A set of experiments was conducted in different electrolytes based on aqueous and aqueous-organic solvents. The experiments were to trace the influence of such settings of electrochemical machining as current density, electrolyte pumping speed, electrolyte temperature, and an electrode gap upon both the dynamics of metal removal and surface quality. Morphology of the obtained surface was examined by an Olympus BX-51Microscope. The dynamics of removing material (stock) from the work piece was inspected. Appropriate adjustments were made to the machining parameters during the machining of 65G steels, and a preferred composition was selected for the working medium. A sufficient design for production tools was proposed. Pitting corrosion was discovered on the surface of the samples in all studied modes of electrolysis. It was observed that switching from aqueous electrolyte to aqueous-organic electrolyte gave lower material removal rate and longer machining time accordingly. At the same time, a reduction in surface roughness was visualized, together with smaller pits and lower density of their distribution. The obtained results may be applied in operation design for electrochemical machining of steels with relatively high carbon contents.

Abstract: Mechanical properties, such as hardness, yield strength and tensile strength, are very often considered as the only key factor for selecting technological parameters of materials machining. Analysis of the microstructure and specific microstructural parameters is not performed until serious problems occur during otherwise common machining processes. This study reports a few case studies, dealing with such problematics, which resulted from underestimation of the knowledge of macrostructure and microstructure of material. It deals with problems such as uncommon surface defects after machining or impossibility to use current technological machining processes when machining new batch of material.

Abstract: In this paper, there is an attempt to monitor and evaluate machining parameters when turning 34CrNiMo6 material under different cooling and lubrication conditions. The machining parameters concerned are temperature of the cutting tool and the workpiece, level of vibrations of the cutting tool, surface roughness of the workpiece, noise levels of the turning process and current drawn by the main spindle motor. Four different experimental machining scenarios were completed, specifically: conventional wet turning process, dry cutting and two additional modes employing cooling by cold air. Experimental data were acquired and recorded by an optimally designed network of sensors. Experimental data were statistically analyzed in order to reach conclusions. According to the research that has been done, although, overall, minimum cutting tool and workpiece temperatures were observed under wet machining, cold air cooling is capable of achieving comparable cooling results to wet machining. The lowest values of surface roughness were achieved by wet machining, whereas the lowest level of cutting tool vibrations were observed under cold air cooling.

Abstract: Drilling experiments of titanium alloy Ti6Al4V were conducted. Taking the speed and feed as the process variables, a set of experimental cutting forces are obtained and compared. From the experimental results it is concluded that within the experimental extent the thrust force and torque of drilling process rises with the feed rate. The lower spindle speed resulted in the greater amount of thrust. Feed rates have greater influence on the thrust force than the spindle speed. The combination of greater feed rate and lower spindle speed results in the maximum amount of thrust. However, combination of greater feed rate and spindle speed resulted in maximum amount of torque.