A normal boundary intersection with multivariate mean square error approach for dry end milling process optimization of the AISI 1045 steel

2016 ◽  
Vol 135 ◽  
pp. 1658-1672 ◽  
Author(s):  
Danielle Martins Duarte Costa ◽  
Tarcísio Gonçalves Brito ◽  
Anderson Paulo de Paiva ◽  
Rafael Coradi Leme ◽  
Pedro Paulo Balestrassi
Keyword(s):  
Process Optimization ◽  
End Milling ◽  
Milling Process ◽  
Mean Square ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Normal Boundary ◽  
1045 Steel ◽  
Multivariate Mean Square Error ◽  
End Milling Process

scholarly journals ANALYSIS OF SURFACE ROUGHNESS MILLED OF STEEL AISI 1045 USING X-BAR AND R CONTROL CHART

2020 ◽  
Vol 5 (6) ◽  
pp. 15-23
Author(s):  
Leonardo Geraldo Leite ◽  
Ítalo de Abreu Gonçalves ◽  
Carlos Henrique De Oliveira ◽  
Tarcísio Gonçalves De Brito ◽  
Sandra Miranda Neves ◽  
...  
Keyword(s):  
End Milling ◽  
Roughness Parameter ◽  
Cutting Speed ◽  
Milling Process ◽  
Cutting Fluid ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide ◽  
End Milling Process

The steel milling AISI 1045 has been gaining prominence in industry in recent years as it allows machined parts to be obtained with low-cost inserts. However, to ensure the final product quality, it is important that the milling for machining procedure be well planned in order to the cutters have their wear minimized in the process, as well as a considerable productivity rate with a zero occurrence of reworked parts or scraps. Thus, this paper presents a study about the quality of the machined surface on the end milling process of AISI 1045 steel using titanium nitride (TiN) coated carbide inserts, optimized for a combined design, using Design of Experiments (DOE). Statistical Process Control (SPC) is applied to analyze the process variations using X-bar and R control charts. The objective of this study is to identify the optimal combination of the input setup such as cutting speed (Vc), feed per tooth (fZ), work penetration (ae) and machining depth (ap) that is capable of minimize the process variation. The response measured is the roughness parameter Ra, observed under the influence of cutting fluid, tool wear, concentration and flow of the cutting fluid as noise. The obtained result was the stability of the Ra roughness for the AISI 1045 steel in end milling process, which is not influenced by noise variables due to Robust Parameter Design used in this study

Selection of Optimal Tool Geometry and Cutting Conditions in End Milling With Graphite as a Solid Lubricant

2004 ◽  
Author(s):  
N. Suresh Kumar Reddy ◽  
P. Venkateswara Rao
Keyword(s):  
Solid Lubricant ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Cutting Fluids ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

Coolants dissipate the heat generated during machining and hence improve productivity, machinability, etc. However, the use of cutting fluids in machining operations may seriously degrade the quality of environment. So, in recent years researchers have started machining with the use of solid lubricants with the aim of improving machining performance and overcome some of the limitations that arise with the use of cutting fluids or while machining dry. This paper deals with an investigation on using graphite as a solid lubricant to reduce the heat generated at the milling zone for improving the surface roughness of the machined AISI 1045 steel. An experimental setup has been developed to maintain constant flow rate of graphite powder continuously on to the workpiece and tool interface zone. The experimental studies have been conducted to see the effect of tool geometry (radial rake angle and nose radius) and cutting conditions (cutting speed and feed rate) on the machining response such as surface finish in solid lubricant assisted machining using four fluted solid TiAlN coated carbide cutters. Results indicate that there is a considerable improvement in the performance of milling AISI 1045 steel using graphite as a solid lubricant when compared with machining with cutting fluids. An attempt has also been made to select optimum tool geometry and cutting conditions in end milling with graphite as a solid lubricant by using the prediction model obtained from these experimental results.

scholarly journals Influence of Graphene Nanosheets on Thermo-Physical and Tribological Properties of Sustainable Cutting Fluids for MQL Application in Machining Processes

2021 ◽  
Author(s):  
Vitor Baldin ◽  
Leonardo R Ribeiro da Silva ◽  
Rogério Valentim Gelamo ◽  
Adres Bustillo Iglesias ◽  
Rosemar Batista da Silva ◽  
...  
Keyword(s):  
Tribological Properties ◽  
Graphene Nanosheets ◽  
Milling Process ◽  
Graphene Sheets ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Cemented Carbide Tool ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Abstract This study investigates the effects of applying two vegetable and one mineral-based cutting fluids with 0.05 %wt and 0.1 %wt dispersion of graphene sheets on the tribosystem generated at the interface between the cemented carbide tool and the AISI 1045 steel workpiece. The fluids are firstly characterized (viscosity, thermal conductivity and diffusivity, and wettability) and tested in reciprocating and ramp milling tests. The results show that the graphene sheets alter the thermo-physical and tribological properties of the cutting fluids; in this case, vegetable-based cutting fluids, even in minimum quantities and with graphene nanoparticles, have a high potential for increasing the efficiency and sustainability of the milling process.

scholarly journals Effect of Graphene Addition in Cutting Fluids Applied by MQL in End Milling of AISI 1045 Steel

Lubricants ◽  
2021 ◽  
Vol 9 (7) ◽  
pp. 70
Author(s):  
Vitor Baldin ◽  
Leonardo Rosa Ribeiro da Silva ◽  
Celso Ferraz Houck ◽  
Rogério Valentim Gelamo ◽  
Álisson Rocha Machado
Keyword(s):  
Tool Life ◽  
Wear Mechanisms ◽  
End Milling ◽  
Fatigue Cracks ◽  
Graphene Sheets ◽  
Cutting Fluids ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Cemented Carbide

The cutting fluids applied to the machining processes by the MQL process aim to reduce the machining temperatures and tool wear as well as improve the surface and dimensional finishing of the parts. To increase the efficiency of these fluids, graphene lubricating platelets are added. This work investigated the performance of three different cutting fluids with graphene sheets added and applied via MQL, considering the tool life, wear, and wear mechanisms acting on TiAlN-coated cemented carbide cutting tools in the end milling of AISI 1045 steel. We evaluated two vegetable- (MQL15 and LB1000) and one mineral-based (MQL14) neat oils and the same fluids with the addition of 0.05 and 0.1%wt graphene nanoplatelets. Dry cuts were also performed and investigated for comparison. The experiments were conducted under fixed cutting conditions (vc = 250 m/min, fz = 0.14 mm/tooth, ap = 1 mm, and ae = 20 mm). The end-of-tool-life criterion followed the guidelines of ISO 8688-1 (1989). To analyze the results, ANOVA and Tukey’s test were applied. The addition of graphene sheets in the vegetable-based cutting fluids effectively increased the lubricating properties, partially reducing the wear mechanisms acting on the tools. In addition, there was a predominance of thermal fatigue cracks and mechanical cracks as well as adhesive and abrasive wear mechanisms on the tools used in the cutting with the MQL15 and MQL14 fluids, indicating greater cyclical fluctuations in temperature and surface stresses.

Reducing Tool Wear in CNC End Milling Operation Using Progressive Feed Rate

2014 ◽  
Vol 592-594 ◽  
pp. 716-723
Author(s):  
K.S. Badrinathan ◽  
L. Karunamoorthy
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Cnc End Milling

This study focuses on the effect of cutting parameters on the tool wear in a CNC end milling operation. Major factors which influence the tool wear are spindle speed, feed rate and depth of cut. Conventionally constant feed rate is used. In this work a concept of progressive feed rate is introduced. AISI 1045 steel has been chosen as it is widely used in manufacturing. Design of Experiments (DOE) technique was adopted to conduct the experiments. Experiments were conducted for both the existing and the proposed feed rate method and the tool wear was compared. A statistical model was developed using Design Expert software. The predicted values were compared with the experimental values and were found to be in close agreement. The model adequacy was checked using ANOVA technique.

Multivariate global index and multivariate mean square error optimization of AISI 1045 end milling

2016 ◽  
Vol 87 (9-12) ◽  
pp. 3195-3209 ◽  
Author(s):  
Robson Bruno Dutra Pereira ◽  
Carlos Andrés Arango Hincapie ◽  
Paulo Henrique da Silva Campos ◽  
Anderson Paulo de Paiva ◽  
João Roberto Ferreira
Keyword(s):  
Mean Square Error ◽  
End Milling ◽  
Mean Square ◽  
Global Index ◽  
Aisi 1045 ◽  
Multivariate Mean Square Error ◽  
Error Optimization

scholarly journals Experimental Design and Data collection of a finishing end milling operation of AISI 1045 steel

Data in Brief ◽  
2016 ◽  
Vol 6 ◽  
pp. 609-613 ◽  
Author(s):  
Luiz Gustavo Dias Lopes ◽  
Tarcísio Gonçalves de Brito ◽  
Anderson Paulo de Paiva ◽  
Rogério Santana Peruchi ◽  
Pedro Paulo Balestrassi
Keyword(s):  
Experimental Design ◽  
Data Collection ◽  
End Milling ◽  
Milling Operation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel
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