Papers by Keyword: Milling

Abstract: The research is concerned with obtaining basic knowledge in the field of machining biocomposite materials with hemp fibers and a matrix in the form of a mixture of polyester and methyl methacrylate resin in a secret ratio. The research was focused on milling technology, or rather side milling. For the needs of the research, 3 milling tools were selected with which experimental measurements were performed. Each tool was different in its type of sharpened geometry, both standard and specialized, including one coated. The experimental measurements focused on the size and course of wear of the cutting edge of the tools, the roughness value of the machined surface and the size and type of delamination of the upper and lower layers of the biocomposite material under investigation. The obtained results helped to evaluate the machinability of the selected hemp biocomposite and at the same time determined the future direction of research with regard to the design of a suitable cutting geometry of the tool and the overall optimization of the machining process during side milling.

Abstract: This study investigates the influence of milling parameters on the material removal rate (MRR) of thick mild steel. The study employs a designed experiment to evaluate the influence of cutting speed, feed rate, and depth of cut on MRR. A total of nine milling experiments are conducted on mild steel using orthogonal array method. The study aims to identify the optimal process parameters for achieving a maximum MRR on mild steel workpieces. The value of signal to noise ratio (SNR) is used to evaluate the optimal values of milling parameters for thick mild steel. Higher-the-better type quality characteristic is used to evaluate the SNR of MRR. Further, MRR is analyzed using ANOVA method to elect the significant milling process parameters based on P-values and fisher coefficient. Depth of cut found the significant followed by feed rate and speed. The contribution of each milling process parameter is also evaluated. Depth of cut contribution is found 66% on MRR of thick mild steel

Abstract: Concrete and cement pastes belong to the most used building materials in human history and represent a solidified mixture of ordinary Portland cement (OPC), water, course and fine-grained aggregates. Fly ash is used as a pozzolanic additive to improve concrete properties. The fly ash property can also be modified by various treatments such as milling or size reduction with sieving. It was suggested that a beneficial pozzolanic reaction with fly ash gives high mechanical properties. Such pozzolanic reaction results in calcium silicate hydrate (C-S-H) phase formation. In this research comparative analytical EPMA study of the paste samples prepared with the addition of the milled and non-milled fly ashes has been performed to elucidate the pozzolanic reaction of the OPC with the milled and non-milled fly ashes. A higher pozzolanic reaction with CSH phase formation was observed in milled fly ash added paste.

Abstract: The main purpose of the research is to study the floating chips produced during mechanical processing. Chips derived from aluminium material cause several difficulties in mechanical processing. Research shows that floating chips clog filters in chip conveyors, resulting in significant downtime in production processes. In this article, cause-effect research has been carried out to find approaches to solving this problem.

Abstract: Carbon Fiber-Reinforced Polymer (CFRP) has been in great demand in the aerospace and automotive industries due to its exceptional strength-to-weight ratio. Machining CFRP is a challenge as dry machining results in high cutting temperature especially with high cutting speeds that compromise the glass transition temperature (Tg) and degrades the matrix resin epoxy. A sustainable cutting environment such as chilled air is utilized as an alternative cutting media in reducing the heat generated during machining process to reduce the tool wear and improved the surface quality of the CFRP. Therefore, this research is conducted to study the progression of uncoated tungsten carbide (WC-Co) tool wear when milling CFRP in a three different cutting conditions which are dry, coolant and chilled air with a constant cutting parameter. The CFRP was milled with a constant speed of 170 m/min, feed rate of 2100 mm/min and 1 mm depth of cut for a total of 6000 mm machining length. It was found that milling in chilled air resulted in the highest flank wear of 0.110 mm, which is higher compared with dry and coolant cutting condition. This is contributed by the additional abrasion of CFRP dust-like chips on the cutting edge of the carbide tool. The presence of the chilled air during milling of CFRP aided in maintaining the surface hardness thus resulted in increasing of tool wear as compared with dry and coolant cutting conditions.

Abstract: This research work is based on the machinability of an Inconel 800 alloy using TiAlN-coating and TiAlN-TiN-coating tools. In the CNC VMC Face milling process feed, depth of cut (DoC), and cutting speed consider input variables and surface roughness, Tool wear is measured for all machining conditions. To enhance the machining conditions a Taguchi L9 Design of Experiment was created. ANOVA analysis was used to identify the important variables influencing Flank wear (tool wear) and surface roughness. The signal-to-noise ratio for the ideal cutting combination was identified by evaluating the optimum surface roughness and tool wear. for the effect of coating, a comparison was done between the findings obtained using both TiAlN-coated and TiAlN-TiN tungsten carbide-coated tools. The best optimum surface roughness and tool wear of the experiment conducted under machining with TiAlN-TiN coated carbide tool resulted in .3433 µm and 128 µm respectively.

Abstract: The single point incremental forming (SPIF) process is a high-trend method for forming a metal in a desirable shape. Forming parameters is an important part of deforming metal sheets. So, while reshaping a metal sheet parameters like tools, toolpath, material properties, sheet thickness, and lubricant were considered. Since the Aluminum sheet is used world widely for the body parts of machines for manufacturing parts. So, an A5052 metallic sheet was formed for the improvement of the depth deforming through the SPIF process. While forming an A5052 sheet lubricant was used constantly. After deforming through the SPIF process, further evaluations of the formed part were examined with the nanoprofiling machine to evaluate the deformed areas. Moreover, the deformed part was analyzed for the nana profiling for the deformation occurs on the surface. Likewise, before forming a part, the A5052 design was computer analysis. The simulation part was studied for fixing the maximum depth.

Abstract: Rapid technological developments have the impact of increasing electromagnetic wave pollution. To reduce this pollution, nickel ferrite (NiFe₂O₄) nanoparticles are made by using mechanical alloying method with high energy milling in a wet state. X-ray diffractometer was used to characterize the crystal structure and the formed phase; scanning electron microscopy was used to characterize surface morphology; and for magnetization, a vibrating sample of magnetometer was used. Meanwhile, the capability to absorb electromagnetic waves in the 2-18 GHz interval was using a vector network analyzer. NiFe₂O₄ nanoparticles have a cubic structure, space group Fd-3m, and a crystal size of 127 nm. The shape of the particles resembles a block and is spherical, measuring about 250-300 nm. At room temperature, NiFe₂O₄ nanoparticles are soft magnetic materials with a magnetic saturation (Ms) of 41.61 emu/g and a coercivity (Hc) of 0.24 kOe. The ability to absorb microwaves, is expressed by reflection loss (RL) ~ -25.81 dB at a frequency (f) 5.16 GHz with a bandwidth (BW) 1.62 GHz, while RL ~ - 18.64 dB at f = 10, 98 GHz with BW = 1.42 GHz.

Abstract: ZnFe₂O₄ nanomaterials were prepared using a solid-state reaction method using high energy milling (750 rpm) for 30 hours and calcined at 1000°C for 5 hours. The characterizations used include XRD, SEM, VSM, and VNA. The measurement results show that the sample has a single phase with a cubic structure. The surface morphology of heterogeneous samples with a particle size of 250-400 nm shows magnetic performance with Ms 2.38 emu/g and Hc 11.29 kOe. The sample also can absorb electromagnetic waves in the frequency range of 2-18 GHz with a minimum RL value of ~-18.79 dB at a frequency of 3.66 GHz, while RL ~-13.32 dB has a bandwidth of 0.9 GHz.

Abstract: Dolomite has great potential to be employed as filler or nanofiller in polymer composite/nanocomposite system. However, the research on dolomite as filler or nanofiller in polymer composite is still immature, requiring further investigations on how to optimize the dispersion of the dolomite in the polymer matrix, thus improving its properties. Particle size reduction of dolomite can be an efficient approach to increase its surface area and facilitate its dispersion and distribution within polymer matrix in order to develop homogeneous composite/nanocomposite system. In this study, the dolomite in pulverized form was obtained from Perlis Dolomite Industry, Malaysia with the average particle size of 150μm. In order to reduce the size of this dolomite, we have initially employed the planetary ball milling method. Results indicate that the particle size of dolomite has been reduced from 150μm to 2μm after subjected to ball milling process. This shows that upon ball milling procedure, the size of dolomite particle is still in micronmeter. Next, the ball milled dolomite was subjected to tip-sonication process to obtain dolomite in nanosize range. Several tip-sonication parameters, which were; amplitude and number of sonication repetition were applied in order to select the best parameters that can produce the finest dolomite powder. SEM and TEM were used to characterize the microstructure of the raw dolomite and the size reduced dolomite. Our results show that when the ball milled dolomite was tip-sonicated, much smaller particle size was obtained. Dolomite with the smallest particle size (~200nm) was obtained when the tip-ultrasonication was performed 3 times at amplitude of 50. These findings indicate that the combination of ball milling and tip-sonication is an efficient method to produce very fine dolomite particles, up to nanosize range. Furthermore, it is a clean, simple method and not involved any toxic and harmful chemicals.