scholarly journals Relationship between Pressure and Output Parameters in Belt Grinding of Steels and Nickel Alloy

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4704
Author(s):  
Nelli Vladimirovna Syreyshchikova ◽  
Danil Yurievich Pimenov ◽  
Munish Kumar Gupta ◽  
Krzysztof Nadolny ◽  
Khaled Giasin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Process ◽  
Belt Grinding ◽  
Flat Surfaces ◽  
Heat Resistant ◽  
Steel Aisi

Belt grinding of flat surfaces of typical parts made of steel and alloys, such as grooves, shoulders, ends, and long workpieces, is a good alternative to milling. Several factors can influence the belt grinding process of flat surfaces of metals, such as cutting speed and pressure. In this work, the importance of pressure in the belt grinding was investigated in terms of technological and experimental aspects. The grinding experiments were performed on structural alloy steel 30KhGSN2/30KhGSNA, structural carbon steel AISI 1045, corrosion-resistant and heat-resistant stainless steel AISI 321, and heat-resistant nickel alloy KHN77TYuR. The performance of the grinding belt was investigated in terms of surface roughness, material removal rate (MRR), grinding belt wear, performance index. Estimated indicators of the belt grinding process were developed: cutting ability; reduced cutting ability for belt grinding of steels and heat-resistant alloy. It was found that with an increase in pressure p, the surface roughness of the processed surface Ra decreased while the tool wear VB and MRR increased. With a decrease in plasticity and difficulty of machinability, the roughness, material removal rate, reduced cutting capacity (Performance index) qper, material removal Q decreased, and the tool wear VB increased. The obtained research results can be used by technologists when creating belt grinding operations for steels and alloys to ensure the required performance is met.

scholarly journals Optimization of Grinding Parameters for the Workpiece Surface and Material Removal Rate in the Belt Grinding Process for Polishing and Deburring of 45 Steel

2020 ◽  
Vol 10 (18) ◽  
pp. 6314
Author(s):  
Fengping Li ◽  
Yao Xue ◽  
Zhengya Zhang ◽  
Wenlei Song ◽  
Jiawei Xiang
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Weighting Coefficient ◽  
Grinding Process ◽  
Feed Speed ◽  
Belt Grinding ◽  
Optimal Value ◽  
Grinding Efficiency

Surface roughness and the material removal rate (MRR) are two important indicators during the grinding process. The former determines the surface quality while the latter reflects the grinding efficiency directly. In this paper, the two indicators are taken into consideration simultaneously and differently by converting them into a comprehensive goal with using weighting objective method. A prediction model was established for each comprehensive goal with each different combination of surface roughness and MRR weighting coefficient. The optimal value of abrasive size, contact force, belt linear speed, and feed speed were obtained under different grinding situations by using a central composite design (CCD) combined with response surface analysis. The experimental results showed that the comprehensive goal can be used effectively as an indicator to control the grinding performance and improve the optimization process.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

scholarly journals Investigation an assisting electrode powder mixed electrical discharge machining of nonconductive ceramic

2021 ◽  
Author(s):  
Dragan Rodic ◽  
Marin Gostimirovic ◽  
Milenko Sekulic ◽  
Borislav Savkovic ◽  
Branko Strbac
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Positive Effects ◽  
Assisting Electrode

Abstract It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

Multi Response Optimization of Process Parameters of Abrasive Water Jet Machining for Stainless Steel AISI 304 Using VIKOR Approach Coupled with Signal to Noise Ratio Methodology

2015 ◽  
Vol 14 (02) ◽  
pp. 107-121 ◽  
Author(s):  
Vedansh Chaturvedi ◽  
Diksha Singh
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Aisi 304 ◽  
Steel Aisi ◽  
Machining Characteristics ◽  
Stainless Steel Aisi ◽  
Experimental Runs

As the population of the world is continuously increasing, demand of the mechanical manufactured products is also increasing. Machining is the most important process in any mechanical manufacturing, and in machining two factors, i.e. material removal rate (MRR) and surface roughness (SR) are the most important responses. If the MRR is high, the product will get desired shape in minimum time so the production rate will be high, but we could not scarify with the surface finishing also because in close tolerance limit parts like in automobile industry, if the surface is rough exact fit cannot take place. The term optimization is intensively related to the field of quality engineering. Abrasive water jet machining is an important unconventional machining, in order to obtain better response, i.e. material removal rate and surface roughness. Various process parameters of AWJM need to be observed and selected to improve machining characteristics. Better machining characteristics can be achieved by optimizing various process parameters of AWJM. This study considers four process control parameters such as transverse speed, standoff distance, abrasive flow rate and water pressure. The response is taken to be material removal rate and surface roughness. The work piece for stainless steel AISI 304 material of size 15 cm × 10 cm × 2 cm is selected for experiments. Sixteen experimental runs (two trials for each experimental runs) were carried out for calculating MRR and SR and average value of these two trials have been taken for analysis. MRR is normalized according to higher-is-better and SR is normalized according to lower is better. The experiment data analysis is done and VIKOR index is found. Finally, the analysis of VIKOR index using S/N ratio is done and found the most significant factor for AWJM and predicted optimal parameters setting for higher material removal rate and lower surface roughness. Verification of the improvement in quality characteristics has been made through confirmation test with the predicted optimal parameters setting. It is found that the determined optimum combination of AWJM parameters gives the lowest VIKOR INDEX which shows the successful implementation of VIKOR Method coupled with S/N ratio in AWJM.

Influence of Flat Lapping Kinematics on Machinability of Ceramics

2013 ◽  
Vol 199 ◽  
pp. 615-620
Author(s):  
Adam Barylski ◽  
Mariusz Deja
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Shape Error ◽  
Roughness Parameters ◽  
Tool Wear Estimation ◽  
Machine Configuration ◽  
Lapping Machine

New tools for flat grinding of ceramics (Al2O3) are presented in the paper. Electroplated CBN tools (B64 and B107) were used in a modified single-disc lapping machine configuration. The results from experiments, such as the material removal rate and surface roughness parameters are presented and analyzed. Numerical simulations, based on the model for the shape error and tool wear estimation in machining with flat lapping kinematics, are also presented. The tool life of electroplated tools can be extended by choosing appropriate parameter K related to the process kinematics.

Optimization of Electric Discharge Machining Parameters of Al-7%Si-4%Mg with 20% of Red Mud Metal Matrix Composites

2014 ◽  
Vol 941-944 ◽  
pp. 1973-1976
Author(s):  
B. Geetha ◽  
K. Ganesan
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Peak Current ◽  
Pulse On Time

An investigation was carried out to find out the influence of process parameters on surface roughness (SR) and material removal rate (MRR) in electric discharge machine of Al-7%Si-4%Mg with 20% of red mud Metal Matrix Composites since electric discharge machining is a thermo-electric machining process, an electronic die sinking electric discharge machine was used to drill holes in the composite work piece, copper is used as tool material. Experiment was carried out to find surface roughness, material removal rate and tool wear rate by varying the peak current, flushing pressure of dielectric fluid and pulse on time. It was found that the surface roughness of composite metal increases with the increase peak current ,pulse on time and flushing pressure due larger and deeper craters on the drilled surface. It was also found that there was increase in metal removal rate with the increase in peak current and flushing pressure and slightly decreases with the increase in pulse on time due carbon deposits on the electrodes. Experimental analysis is carried using Taguchi’s Design of Experiment method with various parameters like peak current, flushing pressure of dielectric fluid and pulse on time to identify the key factors that influence the surface roughness, material removal rate and tool wear rate. It was found that the peak current was the most significant parameter that influences surface roughness, material removal rate and tool wear rate. The Taguchi experiments results confirm the actual results obtained from the numerical calculation.

ELECTRICAL DISCHARGE MACHINING OF Al/7.5% Al2O3 MMCs USING ROTARY TOOL AND Al2O3 POWDER

2017 ◽  
Vol 24 (02) ◽  
pp. 1750018 ◽  
Author(s):  
SAEED DANESHMAND ◽  
BEHNAM MASOUDI ◽  
VAHID MONFARED
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Pulse Current ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Rotary Tool ◽  
Pulse On Time

Nowadays, composites are used in different parts of industries and it is one of the most important subjects. The most widely used reinforcements in metal matrix composites are Al2O3 and SiC fibers and particles which may be used in cutting-edge functional and structural applications of aerospace, defense, and automobile industries. Depending on the type of powder used, composite materials are difficult to machine by conventional cutting tools and methods. The most appropriate way for machining of these composites is electro discharge. For the reason of improving the surface quality, tool wear rate and material removal rate and reducing the cracks on the surface, Al2O3 powder was used. In this study, the effect of input parameters of EDM such as voltage, pulse current, pulse on-time and pulse off-time on output parameters like material removal rate, tool wear rate and surface roughness in both conditions of the rotary tool with powder mixed dielectric EDM and the stationary tool excluding powder mixed dielectric were investigated. The critical parameters were identified by variance analysis, while the optimum machining parameter settings were achieved via Taguchi method. Results show that using of powder mixed dielectric and rotary tool reduce the tool wear rate, surface roughness and the cracks on the surface significantly. It is found also that using of powder mixed dielectric and rotary tool improve the material removal rate due to improved flushing action and sparking efficiency. The analysis of variance showed that the pulse current and pulse on-time affected highly the MRR, TWR, surface roughness and surface cracks.

scholarly journals Multi-Response Optimization of process Parameter in Vertical Milling Machine of EN 31 Using Taguchi Method

2021 ◽  
Vol 23 (11) ◽  
pp. 228-235
Author(s):  
Sunil Kumar ◽  
◽  
P.N . Rao ◽  
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Tool Wear Rate ◽  
Vertical Milling Machine ◽  
En 31

The purpose of this experimental research is to compare the effectiveness of using Taguchi approaches for multi-response optimization of process parameters in Vertical Milling Machine of EN 31 Material intending to minimize surface roughness and tool wear rate while maximizing material removal rate to improve the productivity of the process with coated carbide insert. Taguchi L9 and Annova have been applied for experimental design and analysis. This experiment shows that feed and depth of cut are factors that are important for tool wear, Depth of cut is a notable factor for Material Removal Rate and feed is the most notable factor for surface roughness. Spindle speed has little effect on tool wear rate, surface roughness, and material removal rate. Mathematical models for three response parameters i.e. tool wear rate, surface roughness, and material removal rate were obtained by regression analysis

scholarly journals Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

Materials ◽  
2019 ◽  
Vol 12 (22) ◽  
pp. 3749 ◽  
Author(s):  
Adel T. Abbas ◽  
Neeraj Sharma ◽  
Saqib Anwar ◽  
Faraz H. Hashmi ◽  
Muhammad Jamil ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Optimization Approach ◽  
High Speed Machining

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.

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