A Study of Variation in MRR Influenced by Work Piece Positioning on Copper and Stainless Steel During Wet Chemical Machining

2017 ◽  
Author(s):  
Sarvadnya V. Gandhi ◽  
Rahul Chanmanwar
Keyword(s):  
Stainless Steel ◽  
Work Piece ◽  
Wet Chemical

Identification of Optimum Heating Temperature in Thermal Assisted Turning of Stainless Steel Using Three Different Approaches

2013 ◽  
Vol 393 ◽  
pp. 194-199 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Noor Hawa B. Mohamad Rasdi ◽  
Khairus Syakirah B. Mahmud ◽  
Abdul Hakam B. Ibrahim ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Heating Temperature ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Work Piece ◽  
Optimum Temperature ◽  
Main Concept

Thermal or heat assisted machining is used to machine hard and difficult-to-machine materials such as Inconel and Titanium alloys. The main concept is that localized surface heating of the work-piece reduces the yield strength of the material significantly, making it amenable to plastic deformation and machining. Thus, heat assisted machining has been used for over a century. However, the heating technique and temperature are very much dependent on the type of working material. Therefore, a multitude of heating techniques has been applied over the years including Laser Assisted Machining (LAM) and Plasma Enhanced Machining (PEM) in the industry. But such processes are very expensive and have not been found in wide scale applications. The authors of the current research have therefore looked into the application of a simple Tungsten Inert Gas (TIG) welding setup to perform heat assisted turning of AISI 304 Stainless Steel. Such welding equipment is relatively cheap and available. Also, stainless steel is perennially used in the industry for high strength applications. Hence, it is very important to determine with optimal cutting temperature when applying a TIG setup for heat assisted machining of stainless steel. This paper describes three separate techniques for determining the optimum temperature. All three processes applied the same experimental setup but used different variables for evaluating the best temperature. The first process used vibration amplitude reduction with increment in temperature to identify the desired temperature. The second process used chip shrinkage coefficient to locate the same temperature. And finally, the third process investigated tool wear as a criterion for determining the optimum temperature. In all three cases the three primary cutting parameters: cutting speed, feed, and depth of cut, were varied in the same pattern. The results obtained from all three approaches showed that 450oC was undoubtedly the best temperature for heat assisted machining of stainless steel.

Process Parameter Optimization of Friction Crush Welding (FCW) of AISI 304 Stainless Steel

2017 ◽  
Author(s):  
Gurinder Singh Brar ◽  
Manpreet Singh ◽  
Ajay Singh Jamwal
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Pressure Vessels ◽  
304 Stainless Steel ◽  
Welding Parameters ◽  
Work Piece ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304 ◽  
Friction Stir

AISI 304 stainless steel is one of the grades of steel widely used in engineering applications particularly in chemical equipments, food processing, pressure vessels and paper industry. Friction crush welding (FCW) is type of friction welding, where there is a relative motion between the tool and work-piece. In FCW process, the edges of the work-piece to be joined are prepared with flanged edges and then placed against each other. A non-consumable friction disc tool will transverse with a constant feed rate along the edges of the work-piece, which leads to welding. The joint is formed by the action of crushing a certain amount of additional flanged material into the gap formed by the contacting material. The novelty of present work is that FCW removes the limitations of friction stir welding and Steel work pieces can be economically welded by FCW. Taguchi method of Design of Experiments (DOE) is used to find optimal process parameters of Friction Crush Welding (FCW). A L9 Orthogonal Array, Signal to Noise ratio (S/N) and Analysis of Variance are applied to analyze the effect of welding parameters (welding speed, RPM, tool profile) on the weld properties like bond strength. Grain refinement takes place in friction crush welding as is seen in friction stir welding. Friction crush welding process also has added advantage in reducing distortion and residual stresses.

Mathematical Model for Chip Serration Frequency in Turning of Stainless Steel with Magnetic Damping from Bottom of Tool Shank

2013 ◽  
Vol 393 ◽  
pp. 108-114
Author(s):  
A.K.M. Nurul Amin ◽  
Fawaz Mohsen Abdullah ◽  
Muammer Din Arif ◽  
Israd H. Jaafar
Keyword(s):  
Mathematical Model ◽  
Stainless Steel ◽  
Material Removal ◽  
Control Method ◽  
Research Work ◽  
Chip Morphology ◽  
Work Piece ◽  
Removal Rates ◽  
Serrated Chip ◽  
Tool Shank

Chatter, a violent and often unpredictable relative oscillatory motion between the tool and work-piece, is a serious concern in turning operations. Its occurrence is usually associated with a loud monotonous sound and usually results in increased surface roughness, reduced material removal rates, shortened tool life, and damaged machine-tool bearings. The established theories for chatter are very limited in scope and are often contradicted by empirical evidences. Therefore, chatter avoidance in the past has relied on inefficient techniques like limiting material removal rates or expensive setups such as actuators and ultrasonic vibration damping systems. However, a deeper investigation into chatter formation reveals that chip morphology and segmentation play a significant role during the incidence of chatter. The novel Resonance theory of chatter combines the concept of mode coupling of the machining setup and serrated chip formation, to explain and predict chatter. To validate the postulates of this theory, models for chip serration frequency are essential. At the same time, a reliable and economical chatter control method is required. With this goal, the current research work has developed an empirical mathematical model of chip serration frequency in turning of stainless steel AISI 304 using Response Surface Methodology (RSM). Also, it investigated the influence of damping provided by magnetic field from a permanent ferrite magnet placed beneath the tool shank. The developed chip serration model is in good accord with the experimental data, demonstrating that the empirical model could be used for further chip morphology and chatter analyses.

scholarly journals Mechanical Behavior of ARC Welding using Different Flux Materials

2019 ◽  
Vol 9 (2) ◽  
pp. 4344-4349
Keyword(s):  
Stainless Steel ◽  
Arc Welding ◽  
Large Scale ◽  
Welding Process ◽  
Hardness Test ◽  
Welding Parameters ◽  
Small Scale ◽  
Work Piece ◽  
Welding Operation ◽  
Small Scale Industries

To perform welding process on the material under varying conditions with different flux materials, different welding parameters and further subjecting the material to various suitable tests such as tensile test, hardness test, optical tests and study the characteristics of the material under testing. The tests conducted on the welded work piece it is proposed the suitable parameters under which welding of greater precision can be performed. it is also analyzed the working conditions under which the selected work piece material of stainless steel grade 304 would deviate from its desired characteristics. From the results of the tests it is able to determine the conditions that would reduce the characteristics of the welded work piece. Thus it can be further used for reference when the welding process is done on the same material of stainless steel of grade 304. The electrodes that were chosen for this project were selected by the criteria of widely used and chief material in the welding of various grades of stainless steel. The composition of the chemicals that constitute the electrodes were tribiologically analyzed and studied. The need for high precision welding in large scale as well as small scale industries is relatively high as the threshold for errors in such areas are greatly undesirable. The results of this study would greatly contribute to the reduction of errors and defects in the welding operation.

Development of Mathematical Model for Chip Serration Frequency in Turning of Stainless Steel 304 Using RSM

2012 ◽  
Vol 217-219 ◽  
pp. 2206-2209 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Syidatul Akma Sulaiman ◽  
Muammer Din Arif
Keyword(s):  
Stainless Steel ◽  
Metal Cutting ◽  
Stability Boundary ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Resonance Phenomenon ◽  
System Component ◽  
Work Piece ◽  
Inferior Surface ◽  
Integer Multiple

Chatter is defined as the self-excited violent relative dynamic motion between the cutting tool and work piece. Chatter is detrimental to all machining operations. In metal turning operations it leads to inferior surface topography, reduced productivity, and shortened tool life. Avoidance of chatter has mostly been through reliance on heuristics such as: limiting material removal rates (to stay within the dynamic stability boundary) or selecting low spindle speeds and shallow depth of cuts. However, the correct understanding of the mechanism of chatter formation in metal cutting reveals that chip morphology and segmentation play a predominant role in chatter formation during machining. Chatter is found to appear as a resonance phenomenon when the frequency of chip serration is equal to or integer multiple of the prominent natural frequency/frequencies of the system component(s). Hence, it is important to study the chip serration frequency. At lower cutting speeds the chip is often discontinuous, while it becomes serrated as the cutting speed is increased. It has been identified that the chip formation process at higher speeds also has a discrete nature, associated with the periodic shearing process of the chip. In this paper a statistical technique is proposed to predict the frequency of chip serration as a function of cutting parameters for two different tool overhang values in turning of stainless steel AISI 304 using Response Surface Methodology (RSM).

Improved Surface Integrity during End Milling AISI 316L Stainless Steel Using Heat Assisted Machining

2015 ◽  
Vol 752-753 ◽  
pp. 62-67 ◽  
Author(s):  
Adam Umar Alkali ◽  
Turnad Lenggo Ginta ◽  
Ahmad Majdi Abdul-Rani ◽  
Hasan Fawad
Keyword(s):  
Stainless Steel ◽  
Heat Source ◽  
Surface Integrity ◽  
316L Stainless Steel ◽  
End Milling ◽  
Cutting Speed ◽  
Maximum Temperature ◽  
Work Piece ◽  
Process Conditions ◽  
Hard Part

Different heat source had been investigated for thermally enhanced machining on various engineering materials. Even so, temperature control from the heat source remained a challenged to the process effectiveness.This study used oxyacetylene combustion flame as a heat source in heat assisted machining. The study focuses on the relationships between process conditions; maximum temperature distribution and the surface integrity of 316L stainless steel during preheat machining as compared to dry hard part machining. Two levels of cutting speed 1000rev/min, 630rev/min and feed rates 160mm/min and 100mm/min were investigated while the depth of cutting was maintained constant at 1mm. While preheat machining for 60seconds along the span of the work piece material at cutting speed 1000 rev/min and feedrate 100mm/rev, the average surface finish have improved by 94% over dry hard part machining. This corresponds to flank wear VB = 0.0644mm during heat assisted machining and 0.1425mm for dry hard part machining respectively. Such improvement was accompanied with longer tool life and secured surface integrity which improves the material’s life cycle.

The Study about the Effect of Work-Piece Space on Copper-Cerium Alloy Case Thickness and Component

2013 ◽  
Vol 803 ◽  
pp. 285-288
Author(s):  
Bo Gao ◽  
Jin Yong Xu ◽  
Wen Yao Luo ◽  
Yi Guang Wang ◽  
Cheng Gao
Keyword(s):  
Stainless Steel ◽  
Hollow Cathode ◽  
Case Depth ◽  
Work Piece ◽  
Plasma Surface ◽  
Glow Plasma

In this paper, the author uses double glow plasma surface metallurgy technology, prepares antibacterial stainless steel with copper-cerium case on its surface, does some research on how work-piece space affects Copper-cerium case thickness and component in the case. According to experiment, we find in the range of 10 mm to 25 mm, copper-cerium case depth firstly increase and then decrease with the distance expands; copper-cerium component first rises and then falls with the work-piece space .When the distance is 15mm, hollow cathode effect forms between two plates, we can obtain ideal copper-cerium alley case.

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