PROVIDE THE REQUIRED SURFACE ROUGHNESS PRODUCTS FROM METALLOPOLYMERS FILLED WITH ALUMINUM AT PROCESSING GRINDING

2016 ◽  
Vol 2 (1) ◽  
pp. 162-169 ◽  
Author(s):  
Чепчуров ◽  
Mikhail Chepchurov ◽  
Любимый ◽  
Nikolay Lyubimyy ◽  
Аверченкова ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Aluminum Matrix ◽  
Dimensional Accuracy ◽  
Machine Building ◽  
Depth Of Cut ◽  
Processing Modes ◽  
Material Forming ◽  
The Cost ◽  
Found Model ◽  
Metal Polymer

Currently, machine-building enterprises are increasingly using new composite materials for the production of parts, accessories and repair. One such material is a metallopolymeric composite structure with an aluminum filler. In general, it is an epoxy-dienoic filled with an aluminum matrix excipient. Owing to its flow properties in the uncured state, and hardness and heat resistance when cured, the material is increasingly used in the production. Previous studies have shown the use of metal-polymer material as the material forming the mold parts, as this significantly reduces the cost of equipment for molding plastics. Unlike steel machining modes metallopolymers insufficiently studied, because the material is new, and as yet only finds its field of application. However, in the manufacture of it forming tooling molds required to appoint such process steps and processing modes, which will provide the required dimensional accuracy and surface roughness detail. For a given parameter surface roughness of a metallopolymeric in the processing of grinding was found model of the surface roughness of the parameter rate table movement and the depth of cut.

Effect of SiC Particles on the Machining of Aluminum/SiC Composite

2009 ◽  
Vol 626-627 ◽  
pp. 219-224 ◽  
Author(s):  
Gao Feng Zhang ◽  
Yuan Qiang Tan ◽  
Bi Zhang ◽  
Zhao Hui Deng
Keyword(s):  
Surface Roughness ◽  
Aluminum Matrix ◽  
Volume Ratio ◽  
Damage Mechanism ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Aluminum Metal ◽  
Sic Particles ◽  
Average Grain Size

The objective of this study is to experimentally investigate the effect of reinforced SiC particles on the machining of Aluminum/SiC composite (15% volume ratio of SiC particles with average grain size 15m). Aluminum/SiC composite and aluminum metal were milled by a tungsten carbide endmill in this study. Based on the surface observation and surface roughness inspection, it is found that the machining parameters of Aluminum/SiC composite have optimum values, and that the surface roughness of aluminum/SiC composite is smaller than that of aluminum metal. when feedrate and depth of cut are smaller than limited values, satisfactory surface finish can be attainable, however, as the depth of cut and feedrate increases, the microcracks are first initiated at the interface of SiC particles and aluminum matrix, and then periodically macrocracks are formed on the machined surface, The damage mechanism during the machining of aluminum/SiC are discussed in this paper.

scholarly journals Laser Projection Positioning Improving at a Machine- Building Manufacturing Enterprise Method

2021 ◽  
Vol 2096 (1) ◽  
pp. 012152
Author(s):  
T N Kruglova ◽  
D A Lukyanchikova ◽  
G A Shmelev
Keyword(s):  
Main Product ◽  
Vision System ◽  
Dimensional Accuracy ◽  
Machine Building ◽  
Manufacturing Enterprise ◽  
Projection System ◽  
System Adaptation ◽  
Two Stages ◽  
The Cost ◽  
Formal Statement

Abstract The goal of this work is to research a possibility of laser projection system adaptation to a machine-building manufacturing enterprise. A model example of the use of a computer vision system in production is the task of reducing the labor intensity of installing welded elements on a product, reducing the production time, and reducing the cost of work. A formal statement of the problem is given - to use a laser projection system in the conditions of assembly and welding production for positioning welded elements on the main product with respect to dimensional accuracy. For experimental research, a section of a machine-building production enterprise with a pre-defective product and welded elements was used. The research took place in two stages. As a result of the research, the results were obtained, confirming the efficiency of the method.

scholarly journals Machine tool vibration on dimensional accuracy and surface roughness during milling operation of Al6082 with indexable carbide inserts

2020 ◽  
Vol 18 (2) ◽  
Author(s):  
Paramesh Chamble ◽  
M. R. Bharath ◽  
K. Lokeshaa ◽  
S. Christopher Ezhil Singh
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Dimensional Accuracy ◽  
Eutectic Phase ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machining Parameters ◽  
Tool Vibration ◽  
Milling Operation ◽  
Carbide Inserts

In this research paper, machining tool vibration occurs because of relative motion between the work piece and the cutting tool, which influences the surface finish of the machined part and the lifespan of the cutting tool. Some of the parameters that influence machining tool vibration include feed rate, depth of cut and spindle speed. In this study, experimentation is carried out on a conventional vertical milling machine to investigate the influence of machining tool vibration on surface roughness during face milling operation of Al6082 alloy with indexable carbide inserts. The eutectic phase for joint of Al6082 is β-Al5FeSi eutectic phase. The machining is done in dry condition under the different combinations of Machining parameters designed through Taguchi L9 orthogonal array. The machining tool vibrations are captured with the help of tri-axial accelerometer. Analysis of variance (ANOVA) technique used to formulate the experimental data to analyze the effect of each parameter and machining tool vibration on surface roughness.

scholarly journals Experimental Study on The Effect of Cross Feed of Surface Grinding on the Vibration and the Surface Roughness of Hardened Tool Steel OCR12VM

2020 ◽  
Vol 11 (3) ◽  
pp. 313-322
Author(s):  
Chairul Anam ◽  
◽  
Khairul Muzaka ◽  
Dian Ridlo Pamuji
Keyword(s):  
Surface Roughness ◽  
Tool Steel ◽  
Dimensional Accuracy ◽  
Surface Grinding ◽  
Machining Process ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Hardened Tool Steel ◽  
Stone Type ◽  
Grinding Stone

The grinding process is a machining process to obtain qualified surface roughness levels and high dimensional accuracy. There are two types of processes in the grinding process, namely the roughening and finishing processes. The vibration effect of the roughing process can damage and shorten the life of the tool/machine, while in the finishing process, the effect of vibration will reduce the dimensional accuracy, shape, and surface smoothness of the workpiece. This study aims to determine the effect of crossfeed on the amplitude of vibration and surface roughness of the workpiece on the surface grinding process. The materials used are hardened tool steel OCR12VM with a variety of grinding stone types A46QV and A80LV made of aluminum oxide. The Variables of process parameters are crossfeed (mm / step) and depth of cut (mm). The measurement of vibrations uses an accelerometer, which is processed by the math CAD program in the form of amplitude and frequency. For surface roughness measurements, it is used the MT-301 surface test with 5 sample points and a sample length of 0.8 mm. The results show that the greater the cross-feed value, the bigger the amplitude of the vibration level and the surface roughness of the workpiece. The magnitude of the amplitude of the vibration on the acceleration that occurs in the grinding stone type A46QV starts from 6,7369 -18.7525 g.rms, while the grinding stone type A80LV starts from 5.0904 g.rms to 18.2821 g.rms. The surface roughness achieved in both grit 46 and grit 80 is from N3 to N5.

scholarly journals Optimization of process parameters in turning of nuclear graded steel alloy (AISI-410) for sustainable manufacture

2021 ◽  
Vol 9 ◽  
Author(s):  
Anis Fatima ◽  
◽  
Muhammad Wasif ◽  
Muhammad Omer Mumtaz ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Statistical Model ◽  
Surface Finish ◽  
Metal Cutting ◽  
Functional Performance ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Process Parameter ◽  
Depth Of Cut ◽  
Work Piece

Metal cutting operations involve intense heat generation owing to plastic deformation of the work piece and due to friction at the tool-work piece and tool-chip interface. The heat generated in metal cutting unfavourably affects the quality and thus the functional performance of the product. It is known that quality and functional performance is the function of roughness and dimensional accuracy. To maintain a longer component life, along with the robust material choice, a component should have good surface finish and dimensional accuracy. While, for the organization to monitor and control their environmental issues in a holistic manner, emphasis in adopting eco-friendly practices and protecting environment has been growing continuously across all the business sectors. In this study, an attempt is made to optimize the process parameter of stainless steel AISI-410 alloy, a nuclear graded material, for better surface finish. For this, Taguchi L9 orthogonal array was utilise to identify the process parameter and cutting environment. Analysis of variance (ANOVA) was also conducted to highlight the significant parameter that affects the surface finish most. A statistical model to forecast the surface roughness was also developed and was validated by an experiment with a maximum error of 12%. Results indicates that feed rate is the most critical factor that effects the surface roughness with the contribution of 91.5%, followed by environment with 5.22% contribution, cutting speed and depth of cut with 2.7 % and 0.4 % respectively. The correlation coefficient of 0.9213 and conformation tests reveals that developed statistical model predicts surface roughness with the statistical error limit.

scholarly journals Effect of Machining Parameters on Tool Wear and Surface Roughness In Dry and Wet Machining of Aisi 316 Austenitic Stainless Steel by Taguchi Method

2019 ◽  
Vol 8 (9) ◽  
pp. 3292-3298
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Taguchi Method ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Response Factors ◽  
Aisi 316 ◽  
Optimization Of Cutting Parameters

Stainless steels are widely used to manufacture mechanical components due to excellent mechanical properties. Machining is considered as one of the most critical manufacturing processes in mechanical industry to produce desired shapes and dimensional accuracy of the components. It also affects the performance of the components in its functional requirement. This paper deals with the optimization of cutting parameters in machining operation for AISI 316 austenitic steel with dry and wet environment conditions. The chosen machining parameters in this research are cutting speed, feed rate, and depth of cut as input variables, whereas the response factors are surface roughness and wear rate. Taguchi method with the L9 orthogonal array was used to analyze the process parameters based in dry and wet machining conditions. The Taguchi approach provides the best setting with lower values of surface roughness and wear rate. The regression analysis is performed to obtain a mathematical model of responses in terms of the process parameter. The composite regression optimization gives best setting for dry condition (cutting speed 173 rpm, feed 0.25 mm/rev, and 0.87 mm of the depth of cut) and for wet condition (cutting speed 173 rpm, feed 0.3 mm/rev, and 0.57 mm of the depth of cut). The results show that surface roughness and wear rate are lower in the wet environment than the dry environment.

scholarly journals Experimental Analysis on the Influence and Optimization of μ-RUM Parameters in Machining Alumina Bioceramic

Materials ◽  
2019 ◽  
Vol 12 (4) ◽  
pp. 616 ◽  
Author(s):  
Basem M. A. Abdo ◽  
Saqib Anwar ◽  
Abdulaziz M. El-Tamimi ◽  
Emad Abouel Nasr
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Vibration Frequency ◽  
High Hardness ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Multi Objective Optimization ◽  
Edge Chipping ◽  
Multi Objective ◽  
Input Parameters

Fabrication of precise micro-features in bioceramic materials is still a challenging task. This is because of the inherent properties of bioceramics, such as low fracture toughness, high hardness, and brittleness. This paper places an emphasis on investigating the multi-objective optimization of fabrication of microchannels in alumina (Al2O3) bioceramics by using rotary ultrasonic machining (RUM). The influence of five major input parameters, namely vibration frequency, vibration amplitude, spindle speed, depth of cut, and feed rate on the surface quality, edge chipping, and dimensional accuracy of the milled microchannels was analyzed. Surface morphology and microstructure of the machined microchannels were also evaluated and analyzed. Unlike in previous studies, the effect of vibration frequency on the surface morphology and roughness is discussed in detail. A set of designed experiments based on central composite design (CCD) method was carried out. Main effect plots and surface plots were analyzed to detect the significance of RUM input parameters on the outputs. Later, a multi-objective genetic algorithm (MOGA) was employed to determine the optimal parametric conditions for minimizing the surface roughness, edge chipping, and dimensional errors of the machined microchannels. The optimized values of the surface roughness (Ra and Rt), side edge chipping (SEC), bed edge chipping (BEC), depth error (DE), and width error (WE) achieved through the multi-objective optimization were 0.27 μm, 2.7 μm, 8.7 μm, 8 μm, 5%, and 5.2%, respectively.

Investigations on Machinability and Machining Characteristics of Hybrid Polymer

2014 ◽  
Vol 592-594 ◽  
pp. 461-466 ◽  
Author(s):  
J. Revanthkumar ◽  
Rama Kishore G. Babu ◽  
M. Thirupathi Reddy ◽  
G. Venkatachalam ◽  
A.K. Jeevanantham
Keyword(s):  
Surface Roughness ◽  
Polymer Composites ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Dimensional Accuracy ◽  
Surface Characteristics ◽  
Depth Of Cut ◽  
Hybrid Polymer ◽  
Cashew Nut Shell Liquid

One of the interests in machining is to attain better surface roughness with dimensional accuracy. Polymer composites has been continuously dispatching the conventional materials. Polymer based composites have superior mechanical strength and stiffness such as strength-to-weight ratio, high stiffness-to-weight ratio. Polymer composites are the one which are produced closer to the required shape and further machining is often necessary to achieve the expected surface characteristics. This study targets the machining of hybrid polymer, made in the form of round rod, using general purpose resin and cashew nut shell liquid with varying proportions of CSNL by volume fraction up to 30%. Machining is carried out and the study includes the influence of the various process parameters such as cutting speed and feed with depth of cut kept constant and their importance in deciding the surface roughness. Surface roughness was measured after machining under specified measuring conditions using Talysurf.

scholarly journals A Fuzzy Logic Model for the Analysis of Ultrasonic Vibration Assisted Turning and Conventional Turning of Ti-Based Alloy

Materials ◽  
2021 ◽  
Vol 14 (21) ◽  
pp. 6572
Author(s):  
Riaz Muhammad
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Process Zone ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Zone Temperature

Titanium and its alloys are largely used in various applications due its prominent mechanical properties. However, the machining of titanium alloys is associated with assured challenges, including high-strength, low thermal conductivity, and long chips produced in conventional machining processes, which result in its poor machinability. Advanced and new machining techniques have been used to improve the machinability of these alloys. Ultrasonic vibration assisted turning (UVAT) is one of these progressive machining techniques, where vibrations are imposed on the cutting insert, and this process has shown considerable improvement in terms of the machinability of hard-to-cut alloys. Therefore, selecting the right cutting parameters for conventional and assisted machining processes is critical for obtaining the anticipated dimensional accuracy and improved surface roughness of Ti-alloys. Hence, fuzzy-based algorithms were developed for the ultrasonic vibration assisted turning (UVAT) and conventional turning (CT) of the Ti-6Al7Zr3Nb4Mo0.9Nd alloy to predict the maximum process zone temperature, cutting forces, surface roughness, shear angle, and chip compression ratio for the selected range of input parameters (speed and depth-of-cut). The fuzzy-measured values were found to be in good agreement with the experimental values, indicating that the created models can be utilized to accurately predict the studied machining output parameters in CT and UVAT processes. The studied alloy resulted in discontinued chips in both the CT and UVAT processes. The achieved results also demonstrated a significant decline in the cutting forces and improvements in the surface quality in the UVAT process. Furthermore, the chip discontinuity is enhanced by the UVAT process due to the higher process zone temperature and the micro-impact imposed by the cutting tool on the workpiece.

scholarly journals Surface Characteristics of Machined Polystyrene with 3D Printed Thermoplastic Tool

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2729
Author(s):  
Kamalpreet Sandhu ◽  
Gurminder Singh ◽  
Sunpreet Singh ◽  
Raman Kumar ◽  
Chander Prakash ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Dimensional Accuracy ◽  
Polymeric Materials ◽  
Acrylonitrile Butadiene Styrene ◽  
Surface Characteristics ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
3D Printed

An effort is made in this work to appraise the surface characteristics of machined expandable polystyrene (EPS) with a novel 3D printed thermoplastic acrylonitrile-butadiene-styrene (ABS) tool. Linear grooves on EPS were made on a vertical milling machine that was modified to conduct experiments in the laboratory. The tests were designed as per the Taguchi L9 based factorial design of experimentation while varying process parameters such as depth of cut, spindle speed, and feed rate. The machining responses dimensional accuracy and surface roughness of the machined grooves were studied. Furthermore, the surface topography of the machined specimens was considered to investigate the mechanism of material removal in response to the processing conditions. Moreover, mathematical models developed for the prediction of the output responses showed a significant correlation with the experimental results. The results of the statistical study indicate that the surface roughness is influenced by the spindle speed and dimensional accuracy by the depth-of-cut. Overall, the findings of the experimental work advocated the feasibility of 3D printed thermoplastic tools for machining soft polymeric materials. It can become a useful alternative for mass and batch production.

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