scholarly journals Optimization of CNC End Milling Process Parameters of Low-Carbon Mold Steel Using Response Surface Methodology and Grey Relational Analysis

2021 ◽  
Vol 2021 ◽  
pp. 1-11
Author(s):  
R. Suresh Kumar ◽  
S. Senthil Kumar ◽  
K. Murugan ◽  
B. Guruprasad ◽  
Sreekanth Manavalla ◽  
...  
Keyword(s):  
Regression Analysis ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Machining Process ◽  
Depth Of Cut ◽  
Low Carbon ◽  
Box Behnken Design ◽  
Cnc End Milling

The manufacturing sectors are consistently striving to figure out ways to minimize the consumption of natural resources through rational utilization. This is achieved by a proper understanding of every minute influence of parameters on the entire process. Understanding the influencing parameters in determining the machining process efficacy is inevitable. Technological advancement has drastically improved the machining process through various means by providing better quality products with minimum machining cost and energy consumption. Specifically, the machining factors such as cutting speed, spindle speed, depth of cut, rate of feed, and coolant flow rate are found to be the governing factors in determining the economy of the machining process. This study is focused on improving the machining economy by enhancing the surface integrity and tool life with minimum resources. The study is carried out on low-carbon mold steel (UNS T51620) using Box–Behnken design and grey regression analysis. The optimized multiobjective solution for surface roughness (Ra), material removal rate (MRR), and power consumed (Pc) and tool life is determined and validated through the confirmatory run. The optimized set of parameters in Box–Behnken design and grey regression analysis with that of confirmatory runs shows a 10% deviation that proves the reliability of the optimization techniques employed.

scholarly journals Modeling and optimization of temperature in end milling operations

2019 ◽  
Vol 23 (6 Part A) ◽  
pp. 3651-3660
Author(s):  
Jelena Baralic ◽  
Nedeljko Ducic ◽  
Andjelija Mitrovic ◽  
Pavel Kovac ◽  
Miroslav Lucic
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
Infrared Camera ◽  
Milling Process ◽  
Optimization Techniques ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Machined Surface ◽  
Milling Operations

Milling is one of the most important and most complex cutting machining processes. During the milling process, the cross-section of the chip is variable. Also, all milling operations are interrupted processes. The cutting edge of the mill tooth periodically enters and exits from the contact with the workpiece, which leads to periodic heating and cooling during the machining. This periodic change of temperature significantly affects the process of tool wear and therefore the quality of the machined surface. This paper aims at modeling and optimizing the parameters of the machining process to achieve the minimum temperature. In order to perform optimization, it was necessary to perform temperature measurements for the various parameters of the machining process. An infrared camera was used for the temperature measurement. Then, based on the measured values, the mathematical modeling of the temperature was performed depending on the cutting speed, the feed rate and the depth of cut. This model is then optimized using two different optimization techniques.

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

scholarly journals The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

2018 ◽  
Vol 38 (1) ◽  
pp. 40-44
Author(s):  
Krzysztof Jarosz ◽  
Piotr Niesłony ◽  
Piotr Löschner
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Process Performance ◽  
Turning Process ◽  
Machining Time ◽  
Toolpath Optimization ◽  
The Impact

Abstract In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load.

scholarly journals Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates

2016 ◽  
Vol 2016 ◽  
pp. 1-9 ◽  
Author(s):  
M. Nurhaniza ◽  
M. K. A. M. Ariffin ◽  
F. Mustapha ◽  
B. T. H. T. Baharudin
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimal Cutting Parameters ◽  
Cnc End Milling

The quality of the machining is measured from surface finished and it is considered as the most important aspect in composite machining. An appropriate and optimum machining parameters setting is crucial during machining operation in order to enhance the surface quality. The objective of this research is to analyze the effect of machining parameters on the surface quality of CFRP-Aluminium in CNC end milling operation with PCD tool. The milling parameters evaluated are spindle speed, feed rate, and depth of cut. The L9 Taguchi orthogonal arrays, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) are employed to analyze the effect of these cutting parameters. The analysis of the results indicates that the optimal cutting parameters combination for good surface finish is high cutting speed, low feed rate, and low depth of cut.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ahsana Aqilah Ahmad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Content Type ◽  
Radial Depth

Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

Processing and End Milling Behavioural Study of A356-SiCp Composite

2012 ◽  
Vol 710 ◽  
pp. 338-343 ◽  
Author(s):  
K. Jayakumar ◽  
Jose Mathew ◽  
M.A. Joseph ◽  
R. Suresh Kumar ◽  
P. Chakravarthy
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Pressing Method ◽  
Reinforced Composite ◽  
Effect Of Particle Size

Machining process such as milling receives less attention in the study of machinability of composites due to its interrupted cutting and the complexity of the process. In the present study, A356 aluminium alloy powder reinforced with 10 volume % SiC particles of various sizes (1,12.5 and 25 µm) were synthesized by vacuum hot pressing method and the effect of particle size on the composites were analysed for its mechanical properties and machinability. End milling of these composites were carried out and the surface roughness and resultant cutting force were analysed with the change of machining parameters and varying SiC particle sizes. The minimum cutting force and surface roughness were obtained for a finer particle (1 µm) reinforced composite with higher cutting speed, low feed and depth of cut.

Empirical Expression of Tool Wear When Face Milling 416 SS

2009 ◽  
Author(s):  
Patricia Mun˜oz de Escalona ◽  
Paul G. Maropoulos
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Increase Tool Life ◽  
The Cost

During a machining process, cutting parameters must be taken into account, since depending on them the cutting edge starts to wear out to the point that tool can fail and needs to be change, which increases the cost and time of production. Since wear is a negative phenomenon on the cutting tool, due to the fact that tool life is reduced, it is important to optimize the cutting variables to be used during the machining process, in order to increase tool life. This research is focused on the influence of cutting parameters such as cutting speed, feed per tooth and axial depth of cut on tool wear during a face milling operation. The Taguchi method is applied in this study, since it uses a special design of orthogonal array to study the entire parameters space, with only few numbers of experiments. Also a relationship between tool wear and the cutting parameters is presented. For the studies, a martensitic 416 stainless steel was selected, due to the importance of this material in the machining of valve parts and pump shafts.

Multiobjective Optimization of End Milling HCHCr Using AlCrN PVD Coated Cutters With MOGA and RSMO

2014 ◽  
Author(s):  
Shantisagar K. Biradar ◽  
Geeta S. Lathkar
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Multiobjective Optimization ◽  
End Milling ◽  
Dominant Role ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Depth Of Cut ◽  
Machining Parameters

Here the End milling is studied for optimization of responses such as surface roughness and tool wear while machining HCHCr. These two conflicting responses decide the quality of process; therefore the multiobjective optimization technique is used. The Response Surface Optimizer (RSMO) and Multiobjective Genetic Algorithm (MOGA) were used as the multiobjective optimization techniques. The PVD coating of 2.5 micron AlCrN was used on four flute HSS End milling cutter. Input machining parameters were cutting speed, feed rate, depth of cut and percentage concentration of the solid lubricant MoS2 mixed with SAE-20 base oil. The experimentation was carried out using two level full factorial design concept while ANOVA technique has been used to verify the adequacy of mathematical model. It was found that the cutting speed (V) is having most dominant role on surface roughness and tool wear. The sensitivity analysis was carried out for studying sensitivity of input parameters for the responses.

Machining of VP20ISOF Steel With Resharpened Carbide Tools in End Milling

2013 ◽  
Author(s):  
Ricardo Ribeiro Moura ◽  
Álisson Rocha Machado
Keyword(s):  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
23 Factorial Design ◽  
Coated Tools ◽  
Tool Coating ◽  
Significant Difference ◽  
Coated Cemented Carbide ◽  
Milling Tools

The main objective of the present work is to determine the performance of resharpened integral coated cemented carbide end milling tools. Tools as new and after they have been resharpened were tested, during machining of hard steel used in the mold and die industry. The coatings used were TiAlN and AlCrN. The cutting speed was varied, keeping the depth of cut, the cutting width and the feed per tooth constants. Tests were carried out dry. A 23 factorial design was used, considering the following factors (and levels): cutting speed (80 and 100 m / min), tool coating (TiAlN and AlCrN) and the tool condition (new and reground). The output parameter considered is the tool life (wear rate). At the end of the tool life the wear mechanisms were analyzed within a Scanning Electron Microscopy - SEM. The results showed that in general the AlCrN coated tools outperformed the TiAlN. The performance of resharpened tools was very similar to the new tools, and statistically there is no significant difference between their tool lives.

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