Kinematics Analysis of the Chipping Process Using the Circular Diamond Saw Blade

1999 ◽  
Vol 121 (2) ◽  
pp. 257-264 ◽  
Author(s):  
H. D. Jerro ◽  
S. S. Pang ◽  
C. Yang ◽  
R. A. Mirshams
Keyword(s):  
Kinematic Model ◽  
Chip Thickness ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
New Model ◽  
Spacing Ratio ◽  
Diamond Saw ◽  
D Values ◽  
Saw Blade ◽  
Machining Parameter

One of the primary goals in the design of a diamond blade cutting system is to reduce the cutting force. By understanding the fundamentals of the kinematics of the sawing operation, these forces can be lowered and even optimized with respect to the machining parameters. In this work the material chipping geometries have been mathematically defined and derived through kinematic analysis. These geometries are bounded by four curves and depend on the parameters: depth of cut h, blade diameter D, transverse rate of the workpiece νT, peripheral speed of the saw blade νP, and grit spacing λ. From these chipping geometries, chip area and thickness relations have been obtained. A relation for the mean chip thickness to grit spacing ratio (tc/λ) has also been obtained as a function of the nondimensional machining parameter ratios, h/D and νT/νP. The effects of these parameters on tc were also investigated. It was found that increasing ω and D, reduces the chip thickness. Contrarily, increasing νT, λ, and h, increases the magnitude of the chip thickness. A review of older chipping models was performed, comparing well with the developed model. The results show an excellent agreement between the new model and the older ones. However, at moderately small to large h/D values the new model yields a more exact result. Thus, for h/D values greater than 0.08, it is recommended that the kinematic model be used to compute tc and other pertinent sawing parameters (i.e., grit force and grinding ratio) which are a function of tc.

scholarly journals OPTIMASI PARAMETER PERMESINAN TERHADAP WAKTU PROSES PADA PEMROGRAMAN CNC MILLING DENGAN BERBASIS CAD/CAM

2016 ◽  
Vol 6 (1) ◽  
Author(s):  
I G.N.K. Yudhyadi ◽  
Tri Rachmanto ◽  
Adnan Dedy Ramadan
Keyword(s):  
Cutting Speed ◽  
Operation Time ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine ◽  
Machining Parameter

Milling process is one of many machining processes for manufacturing component. The length of time in the process of milling machining is influenced by selection and design of machining parameters including cutting speed, feedrate and depth of cut. The purpose of this study to know the influence of cutting speed, feedrate and depth of cut as independent variables versus operation time at CNC milling process as dependent variables. Each independent variable consists of three level of factors; low, medium and high.Time machining process is measured from operation time simulation program, feed cut length and rapid traverse length. The results of statistically from software simulation MasterCam X Milling, then do comparison to CNC Milling machine.  The data from experiments was statistical analyzed by Anova and Regression methods by software minitab 16.Results show that the greater feedrate and depth of cut shorten the operation time of machinery, whereas cutting speed is not significant influence. Depth of cut has the most highly contribution with the value of 49.56%, followed by feedrate 43% and cutting speed 0.92%. Optimal time of machining process total is 71.92 minutes, with machining parameter on the condition cutting speed is 75360 mm/minutes, feedrate is 800 mm/minutes and depth of cut = 1 mm. Results of comparison time machining process in software Mastercam X milling with CNC Milling machine indicates there is difference not significant with the value of 0,35%.

Multi Response Optimization of Setting Process Variables in Face Milling of ZE41 Magnesium Alloy using Ranking Algorithms and ANOVA

2019 ◽  
Vol 11 (1) ◽  
Author(s):  
S.P. Sundar Singh Sivam ◽  
V.G. Umasekar ◽  
Ganesh Babu Loganathan ◽  
D Kumaran ◽  
K. Saravanan
Keyword(s):  
Cutting Speed ◽  
Chip Thickness ◽  
Numerical Control ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Setting Process ◽  
Order Preference ◽  
Tool Diameter ◽  
Cutting Point

This study presents the optimization of machining parameters on ZE41 Mg alloy fabricated by gravity die casting and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). Focus on the optimization of machining parameters using the technique to get minimum surface roughness, cutting force, thermal stress, residual stress, chip thickness and maximum MRR. A number of machining experiments were conducted based on the L27 orthogonal array on computer numerical control vertical machining center. The experiments were performed on ZE41 using cutting tool of an ISO 460. 1-1140-034A0-XM GC3 of 20, 25 and 30mm diameter with cutting point 140 degrees, for different cutting conditions. TOPSIS and ANOVA were used to work out the fore most important parameters cutting speed, feed rate, depth of cut and tool diameter which affect the response. The expected values and measured values are fairly close. Finally, the study for optimizing machining process is surveyed and results show improvement in real experiments.

An Investigation of Workpiece Temperature in Orthogonal Turn-Milling Compound Machining

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Fangyu Peng ◽  
Yizhi Liu ◽  
Sen Lin ◽  
Rong Yan ◽  
Sheng Yang ◽  
...  
Keyword(s):  
Heat Source ◽  
Orthogonal Experiment ◽  
Test Validity ◽  
Chip Thickness ◽  
Depth Of Cut ◽  
Heat Conducting ◽  
Machining Parameters ◽  
Workpiece Temperature ◽  
Milling Tool ◽  
Turn Milling

A thermal model estimating workpiece temperature in orthogonal turn-milling compound machining for the case with noneccentricity between rotation axes of workpiece and tool has been established in this paper. Milling tool and machining history were discretized into infinitesimal elements of equal size to deal with complicated cutter geometry and intermittent cutting procedure. The geometries of milling tool and workpiece were analyzed to calculate the instantaneous chip thickness, axial depth of cut, and angles of cutting entry and exit. Heat source during cutting process was considered as instantaneous moving rectangular heat source and heat conducting function in infinite solid thermal conductivity was developed. Experiments measuring cutting force and workpiece temperature were launched to test validity of this model and figure out the importance of effects those factors have on workpiece temperature from variance analysis of orthogonal experiment results. Furthermore, simulations to calculate peak temperature of workpiece were carried out by this model with relevant machining parameters and the results matched conclusions from experiment well.

A Novel MCDM Approach for Simultaneous Optimization of some Correlated Machining Parameters in Turning of CP-Titanium Grade 2

2016 ◽  
Vol 22 ◽  
pp. 94-111 ◽  
Author(s):  
Akhtar Khan ◽  
Kalipada Maity
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Pure Titanium ◽  
Cutting Speed ◽  
Simultaneous Optimization ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Titanium Grade ◽  
The Impact ◽  
Machining Parameter

The present work explores the application of a novel Multi-Criteria Decision Making (MCDM) based approach known as VIKOR analysis combined with Taguchi technique for simultaneous optimization of some correlated cutting variables in turning of commercially pure titanium grade 2 using uncoated carbide inserts. The experiments have been carried out according to Taguchi’s L27 orthogonal array. Three input variables viz. cutting speed, feed rate and depth of cut have been taken at three different levels. The impact of these cutting variables on cutting force, surface quality and material removal rate has been investigated. The optimal combination of machining parameters has been evaluated to minimize the cutting force and to maximize the surface finish and production rate using MCDM based VIKOR analysis method. ANOVA (analysis of variance) test has been performed to determine the most influencing cutting variable on overall quality measure i.e. VIKOR index (Qi). The optimal setting of machining variables has been shown using main effects plot for S/N ratio for Qi. The results of ANOVA exhibit that the cutting speed is the governing machining parameter followed by feed rate on overall quality index (Qi). The minimum (desirable) value of Qi is achieved at the parametric combination of v3-f1-d3 i.e. cutting speed (110 m/min), feed rate (0.08 mm/rev) and depth of cut (0.4 mm) respectively. The feasibility of the proposed methodology has been verified by conducting a confirmation test.

Kinematic Model of Dynamic Drilling Process

2004 ◽  
Author(s):  
Jochem C. Roukema ◽  
Yusuf Altintas
Keyword(s):  
Mathematical Model ◽  
Rigid Body ◽  
Kinematic Model ◽  
Chip Thickness ◽  
Body Motion ◽  
Depth Of Cut ◽  
Force Model ◽  
Drilling Process ◽  
Structural Vibrations ◽  
Radial Depth

A mathematical model of the torsional-axial chatter vibrations in drilling is presented. The model considers the exact kinematics of both rigid body, and coupled torsional and axial vibrations of the drill. The drill is modeled as a pretwisted beam that exhibits axial deflections due to torque and thrust loading. A mechanistic cutting force model is used to model the cutting torque and thrust as a function of feedrate, speed, radial depth of cut, and drill geometry. The drill rotates and feeds axially into the workpiece while the structural vibrations are excited by the cutting torque and thrust force. The exact location of the drill edge is predicted using the model, and the generated surface is digitized at discrete time intervals. The distribution of chip thickness, which is affected by both rigid body motion and structural vibrations, is evaluated by subtracting the presently generated surface from the previous one. The model considers nonlinearities in cutting coefficients, tool jumping out of cut and overlapping of multiple regeneration waves. The dynamic chip thickness obtained from the true kinematics model allows simultaneous prediction of force, torque, power and dimensional form errors left on the surface. The time domain simulation model allows prediction of stability lobes. The paper provides details of the mathematical model, supported by experimental results of both stable and unstable cuts.

Surface Characteristics of Indonesian Cortical Bone Screw

2014 ◽  
Vol 893 ◽  
pp. 349-352
Author(s):  
Pringgo Widyo Laksono ◽  
Muslim Mahardika ◽  
Suyitno ◽  
Punto Dewo
Keyword(s):  
Cortical Bone ◽  
Cutting Tools ◽  
Surface Characteristics ◽  
Bone Screws ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Orthopedic Implant ◽  
Bone Screw ◽  
Cortical Screw ◽  
Machining Parameter

Machining processed with various conditions form the surface characteristics of materials. Material processes needed for forming parts such as bone screws. This paper presents surface characteristics of bone screw for orthopedic implant that processed by conventional turning machine with various conditions. Manufacturing production in conventional way of bone screw connector is expected to produce same geometry, dimensions and quality as well as the product from abroad. The screws design type that used for cortical bone orthopedic implant known as cortical bone screw. Cortical screws have fine threads along the shaft and are designed to anchor in cortical bone. In this research, screws were made of stainless steel 316L which mounted on the horizontal lathe and the head manufactured by punching machine. Bone screws which used for interfragmentary bone surgery manufactured by lathe machine with various conditions such as various thread per inch, various cutting tools angle, various cutting tools properties and also various depth of cut. So this research focus on the extent to which the influence of machining parameters namely cutting speed, depth of cut, feed rate, cutting angle, number of thread and tool selection to the surface characteristic of the bone screw. Based on the result from the different machining parameter, they are affecting to the quality of the cortical screw on the microstructure, and the surface roughness.

Multi-Objective Optimization of CNC Turning Machining Parameters

2014 ◽  
Vol 1016 ◽  
pp. 172-176 ◽  
Author(s):  
Sharad Kumar Pradhan ◽  
Surendra Kumar Saini
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Multi Objective Optimization ◽  
Cnc Turning ◽  
Multi Objective ◽  
Machining Parameter

An experimental investigation into CNC turning operation on Brass C36000 alloy as work piece material which is widely used for various industrial applications is performed. Multi objective optimization is carried out to find out the influencing machining parameters among spindle speed (rpm), feed (mm per revolution) and depth of cut (mm) for CNC turning of Brass C36000 alloy with surface finish and Material Removal Rate as performance parameters using Taguchi method. Taguchi orthogonal array [L27(33)] is used for the experimental design. All experiments are conducted using EMCO Concept Turn 250 machine tool with carbide insert cutting tool. The optimization result shows that feed is the most significant turning machining parameter for surface roughness while depth of cut has high influence on material removal rate followed by spindle speed during CNC turning of Brass C36000 alloy. Above results is further validated using ANOVA approach.

Optimisation of End Milling Machining Parameters Using the Taguchi Method and ANOVA of AlSi/AlN Metal Matrix Composite Material

2016 ◽  
Vol 701 ◽  
pp. 200-204 ◽  
Author(s):  
Mohamad Sazali Said ◽  
Jaharah A. Ghani ◽  
Mohd Asri Selamat ◽  
Nurul Na'imy Wan ◽  
Hassan C.H. Che
Keyword(s):  
Matrix Composite ◽  
Tool Life ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
High Feed ◽  
Machining Parameter ◽  
Cutting Speeds

Abstract. The purpose of this research is to determine the optimum machining parameter for Aluminium silicon alloy (AlSi) matrix composite, which has been reinforced with aluminium nitride (AlN), with three types of carbide inserts present. Experiments were conducted at various cutting speeds, feed rates and depths of cut, according to the Taguchi orthogonal array L27. The signal-to-noise (S/N) ratio and analysis of variance are applied to study the characteristic performance of cutting speeds, feed rates, depths of cut and types of tool in measuring the tool life during the milling operation. The analysis of wear was done using a Sometech SV-35 video microscope according to ISO 3686. Through Taguchi analysis, it is concluded that a combination of high feed rate, high depth of cut, low cutting speed and insert TiB2 give a longer tool life. Therefore, the cutting speed of 230 m/min, feed rate of 0.8 mm/tooth, depth of cut of 0.5 mm and type of insert of TiB2 were the optimum machining parameters. These optimum parameters will help the automotive industry to have a competitive machining operation from both economical and manufacturing perspectives.

Investigation of the Effects of Machining Parameters and Air Blowing on Surface Topography in High Speed End Milling of Silicon

2012 ◽  
Vol 576 ◽  
pp. 11-14
Author(s):  
A.K.M. Nurul Amin ◽  
Noor Syairah Khalid ◽  
Siti Nurshahida Mohd Nasir ◽  
Muammer D. Arif
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
End Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ductile Regime Machining ◽  
Milling Machines ◽  
Air Blowing ◽  
Electron Microscopes ◽  
Machining Parameter

Machining of silicon is an expensive affair because its inherent brittleness leads to subsurface crack generation. Research endeavours have therefore focused on ductile mode machining of silicon to obtain crack free machined surfaces with roughness as low as 0.22 µm or even below, hence eliminating the need for subsequent polishing/grinding operations. However, most of these research works utilized expensive ultraprecision machines and tools. This research aimed at determining the viability of using conventional milling machines with diamond coated tools, high speed attachments, and air blowing mechanisms in order to achieve ductile regime machining of silicon. Spindle speed, depth of cut, and feed rate, ranges: 60,000 to 80,000 rpm, 10 to 20 µm, and 5 to 15 mm/min respectively, were considered as the independent machining parameters. Compressed air at 0.35 MPa was also provided to prevent chip deposition on the finished surfaces. The resultant surfaces were analysed using Optical and Scanning Electron Microscopes. Then, the influence of each machining parameter on surface roughness was investigated. From the analyses it was concluded that all three machining parameters and air blowing had significant influence on the surface topography and integrity of silicon.

scholarly journals Design and Development of a Numerical Model and Study on Kinematic Analysis of a Circular Diamond Saw Blade for Ceramics

2021 ◽  
Vol 9 (12) ◽  
pp. 686-691
Author(s):  
N Balasubramanyam
Keyword(s):  
Tangential Force ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Power Model ◽  
Diamond Tools ◽  
Diamond Saw ◽  
Solid Works ◽  
Saw Blade ◽  
Cut Depth

Abstract: Diamond tools are currently being used by an increasing number of architects, miners and construction engineers because they are faster and easier to use than older, more traditional instruments like sledge hammers and pneumatic and hydraulic jacks. Bridge and highway surfaces are cut with diamond asphalt and concrete cutting machines to provide for quick, clean, and easy section removal and replacement. The entire cost is reduced since diamond tools take less time and manpower The experiment is carried out to validate the performance of diamond saw blades by taking into consideration characteristics such as normal force, tangential force, cutting speed, cut depth, and peripheral velocity. In present exploration work we are introductory phase of plan conclusion of a jewel device cutting edge with various segmental like 8,12,16,20 corn meal by utilizing Solid works programming we are planning the apparatus cutting edge after that we are imported in Ansys Software for Analysis reason. Computing the necessary qualities for examination and estimations of earthenware tiles likewise are some other stone molecule. Another power model of cutting is presented and inferred numerical demonstrating for chip thickness. Identical chip thickness to coarseness space proportion is gotten from the new power model another outspread opening like profile is presented. Fragmented sort jewel saw sharp edge with the measurement of 400 mm and different portion, for example, 8, 12, 16 and 20 are planned in Solid works effectively. An examination study between existing roundabout outspread space and cone like opening is done to decide deformity, stress dispersion, vibration and temperature conveyance.

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