scholarly journals THE INFLUENCE OF FEED RATE ON SURFACE ROUGHNESS OF TIC–WC CARBIDE AND AL2O3 CERAMICS SAWN-OFF WITH INNER EDGE OF DIAMOND DISC

2010 ◽  
Vol 2 (4) ◽  
pp. 88-90
Author(s):  
Raimundas Mikolaitis ◽  
Valdas Bukauskas ◽  
Vadim Mokšin ◽  
Vytautas Striška
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Tungsten Carbide ◽  
Feed Rate ◽  
Aluminium Oxide ◽  
Cutting Process ◽  
Feed Speed ◽  
Average Roughness ◽  
Cutting Machine ◽  
Diamond Disc

The paper presents results of measurements of surface roughness of titanium-tungsten carbide (T14K8) and aluminium oxide (Al2O3) ceramics surfaces sawn-off with inner edge of diamond disc. The cutting process was performed by cutting machine “АЛМАЗ-4” with 60/40 grain size disc. The dependence of average roughness Ra of the sawn-off surface on feed speed of the workpiece was established.

Experimental Investigation of Surface Roughness Using Uncoated and Coated Tungsten Carbide Cutting Tool in Turning Operation

2021 ◽  
Vol 39 (5A) ◽  
pp. 768-778
Author(s):  
Frzdaq N. Thamer ◽  
Ali A Khleif ◽  
Farhad M. Othman
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Substantial Effect ◽  
Cutting Process ◽  
Dry Cutting ◽  
The Impact

 The cutting process is an important process of industrialization. It is requisite to using advantage quality cutting tools in order to preserve the type of product. Coating on the cutting tool has a substantial effect in terms of mechanical properties and the end results of the product. The cutting tool can be manufactured in various material types, but today's cemented tungsten carbide is the most commonly used material in the tool industry because its properties comply with manufacturers' requirements. This study investigates the impact of an Al2O3 coated cutting tool relative to an uncoated cutting tool on the dry cutting process. Different parameters are used in the cutting process when cutting the metal. The cutting parameters used are feed rate and cutting speed, An analysis of the effects of these parameters on the surface roughness. In this analysis, the surface roughness are measured for components turned from steel1040, The L9 Taguchi orthogonal arrays and analyses of variance (ANOVA) was employed to analyze the influence of these parameters. In the case of (uncoated, Al2O3 coated tool), the better surface roughness (SR) with used feed rate (0.05 mm / rev) and cutting speed (140 m/min) where the roughness value was (0.81μm) and (0.78μm) Respectively. The results of this study indicate that the ideal parameters combination for the better surface finish was high cutting speed and low feed rate.

In Situ: A Novel Approach for the Production of Micro Holes

2010 ◽  
Vol 126-128 ◽  
pp. 885-890
Author(s):  
K.P. Somashekhar ◽  
N. Ramachandran ◽  
Jose Mathew
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
Machining Parameters ◽  
Average Roughness ◽  
Arithmetic Average ◽  
Quantitative Correlation ◽  
Good Surface ◽  
Novel Approach ◽  
Micro Holes

This work is on the preparation of microelectrodes for μ-EDM operation using μ-WEDG process. Electrodes of Ø500 μm are fabricated with various discharge energy machining conditions. Effects of gap voltage, capacitance & feed rate on the surface finish of the electrodes and overcut of the thus produced micro holes are investigated. The profile of microelectrodes is measured using surface roughness tester with 2μm stylus interfaced with SURFPAK software. The study demonstrated that for brass electrodes an arithmetic average roughness value as low as 1.7μm and an overcut of 3 µm could be achieved. The significant machining parameters are found using ANOVA. Surface of the produced microelectrodes are examined using Scanning Electron Microscope. μ-WEDG process parameters could be adjusted to achieve good surface integrity on microelectrodes. Experimental results showed that the surface roughness of microelectrodes depended primarily on feed rate of the electrode. The observations showed the clear and quantitative correlation existing between the micrometer level surface quality and process parameters. The resulting microelectrodes are found to be of exceptionally high quality and could be used for μ- EDM operation on different types of work materials.

Investigations on surface roughness and microhardness of turned AM alloy

2020 ◽  
pp. 095440622097616
Author(s):  
Sunil Dutta ◽  
NSK Reddy
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Average Roughness ◽  
Study Results ◽  
Superior Surface ◽  
Input Variables ◽  
Response Variables

Manufacturers in different sectors look for materials exhibiting good mechanical properties, high machinability, and superior surface integrity. The machinability of Mg alloys is one of the vital aspects which requires an exhaustive survey during their selection for different applications. The study examines the surface integrity of a fabricated AM alloy (Mg alloy with 7 wt%Al-0.9 wt%Mn) through dry turning. During the experiments, the input variables of turning viz. cutting speed( v), depth of cut (DOC), and feed( f) is altered and applied to the workpiece. The data obtained for the two response variables viz. surface roughness and microhardness accentuate the maximum influence of feed, followed by DOC and speed. For validation a two-stage methodology was adopted; In the first stage, the validation was done with the help of Analysis of variance (ANOVA); the results show the % contribution of feed, speed, and DOC on average roughness is 66.94%, 5.91%, and 27.23% and on microhardness is 47%, 8.3%, and 44.57%, respectively. Subsequently, in the second stage, the surface plots are drawn for both the response variables to ascertain the ANOVA outcomes; the shape of the plots corroborates the experimental and ANOVA results. The study results provide vital insights for parameter selection to get improved results on surface roughness and microhardness during machining of AM alloy.

scholarly journals Optimization of machining parameters in face milling using multi-objective Taguchi technique

2018 ◽  
Vol 12 (2) ◽  
pp. 104-108 ◽  
Author(s):  
Yusuf Fedai ◽  
Hediye Kirli Akin
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Taguchi Technique ◽  
Average Roughness ◽  
Multi Objective ◽  
Control Factors ◽  
Average Maximum

In this research, the effect of machining parameters on the various surface roughness characteristics (arithmetic average roughness (Ra), root mean square average roughness (Rq) and average maximum height of the profile (Rz)) in the milling of AISI 4140 steel were experimentally investigated. Depth of cut, feed rate, cutting speed and the number of insert were considered as control factors; Ra, Rz and Rq were considered as response factors. Experiments were designed considering Taguchi L9 orthogonal array. Multi signal-to-noise ratio was calculated for the response variables simultaneously. Analysis of variance was conducted to detect the significance of control factors on responses. Moreover, the percent contributions of the control factors on the surface roughness were obtained to be the number of insert (71.89 %), feed (19.74 %), cutting speed (5.08%) and depth of cut (3.29 %). Minimum surface roughness values for Ra, Rz and Rq were obtained at 325 m/min cutting speed, 0.08 mm/rev feed rate, 1 number of insert and 1 mm depth of cut by using multi-objective Taguchi technique.

The Study of Surface Roughness and MRR of Mild Steel Using Manual Plasma Arc Cutting Machining

2012 ◽  
Vol 576 ◽  
pp. 3-6 ◽  
Author(s):  
R. Bhuvenesh ◽  
M.S. Abdul Manan ◽  
M.H. Norizaman
Keyword(s):  
Surface Roughness ◽  
Removal Rate ◽  
Cutting Process ◽  
Material Surface ◽  
Plasma Arc ◽  
Manufacturing Companies ◽  
Average Roughness ◽  
Plasma Arc Cutting ◽  
Before And After ◽  
Manual Plasma

Manufacturing companies define the qualities of thermal removing process based on the dimension and physical appearance of the cutting material surface. Therefore, the roughness of the surface area of the cutting material and the rate of the material being removed during the manual plasma arc cutting process was importantly considered. Plasma arc cutter Selco Genesis 90 was used to cut the specimens made from Standard AISI 1017 Steel manually based on the selected parameters setting. Two different thicknesses of specimens with 3mm and 6mm were used. The material removal rate (MRR) was measured by determining the weight of the specimens before and after the cutting process. The surface roughness (SR) analysis was conducted to determine the average roughness (Ra) value. Taguchi method was utilized as an experimental layout to obtain MRR and Ra values. The results reveal that for the case of manual plasma arc cutting machining, the SR values are inversely proportional to the MRR values. The quality of the surface roughness depends on the dross peak that occurred during the cutting process.

scholarly journals Effect of Cutting Depth and Feed Speed to Surface Roughness in Lathe Process of Screw Conveyor Shaft (Case Study: PT. RAPP)

2020 ◽  
Vol 64 (2) ◽  
pp. 59-62
Author(s):  
Junaidi Abdul Khair ◽  
◽  
Deni Pranata ◽  
Ujang Nurhadek ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Rotational Speed ◽  
High Speed ◽  
Feeding Rate ◽  
Production Quality ◽  
Screw Conveyor ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Turning Process

The metalworking process is one of the most important things in manufacturing of machine components, such as lathe process. Therefore, it is required continuously innovation to improve production quality. There are several ways to do this, for example by choosing the right type of tool, depth of cut, and spindle speed. In turning process for the production of goods is very important to produce a precision product in accordance to desiring of size and roughness. The turning speed of a lathe has a type of spindle rotation rate that is used according to production requirements, which uses a rotational speed that can be changed the rate of rotation of the machine, in order to determine the level of surface roughness in the turning process. One is affected the optimal conditions of the turning speed and feeding rate. In this paper, the variations of different rotational speed levels of low speed, medium speed and high speed according to variations of feeding rate in order to know the difference in roughness results for the screw conveyor shaft operation. The roughness was measured on the surface turning process using a reference of surface roughness stand comparator (ISO2632 / I-1975). The result of test revealed the greater speed of feed rate, the greater value of roughness. Reversely, the smaller speed of feed rate affected the lower roughness value.

scholarly journals Research on selection of abrasive grain size and cutting parameters when grinding of interrupted surface using aluminum oxide grinding wheel with ceramic binder

2022 ◽  
pp. 93-102
Author(s):  
Do Duc Trung ◽  
Le Dang Ha
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Aluminum Oxide ◽  
Feed Rate ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Testing Sample ◽  
Abrasive Grain ◽  
Ceramic Binder

In this article, a study on intermittent surface grinding using aluminum oxide grinding wheel with ceramic binder is presented. The testing material is 20XH3A steel (GOST standard – Russian Federation). The testing sample has been sawn 6 grooves, with the width of each groove of 10 mm, the grooves are evenly distributed on the circumference of sample. The testing sample resembles a splined shaft. An experimental matrix of nine experiments has been built by Taguchi method, in which abrasive grain size, workpiece speed, feed rate and depth of cut were selected as input variables. At each experiment, surface roughness (Ra) and roundness error (RE) have been measured. Experimental results show that the aluminum oxide and ceramic binder grinding wheels are perfectly suitable for grinding intermittent surface of 20XH3A steel. Data Envelopment Analysis based Ranking (DEAR) method has been used to solve the multi-objective optimization problem. The results also showed that in order to simultaneously ensure minimum surface roughness and RE, abrasive grain size is 80 mesh, workpiece speed is 910 rpm, feed rate is 0.05 mm/rev and depth of cut is 0.01 mm. If evaluating the grinding process through two criteria including surface roughness and RE, depth of cut is the parameter having the greatest effect on the grinding process, followed by the influence of feed rate, workpiece speed, and abrasive grain is the parameter having the least effect on the grinding process. In addition, the effect of each input parameter on each output parameter has also been analyzed, and orientations for further works have also been recommended in this article

INVESTIGATION OF SURFACE MORPHOLOGY OF DRILLED CFRP PLATES AND OPTIMIZATION OF CUTTING PARAMETERS

2020 ◽  
Vol 27 (09) ◽  
pp. 1950209
Author(s):  
ÖMER ERKAN ◽  
GÖKHAN SUR ◽  
ENGIN NAS
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Design Method ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Feed Speed ◽  
Reinforced Polymer ◽  
Cfrp Composite ◽  
Optimization Of Cutting Parameters ◽  
Full Factorial

In this study, the carbon fiber reinforced polymer (CFRP) composite material was drilled using different parameters ([Formula: see text] and [Formula: see text] Point Angle, 30, 60 and [Formula: see text] cutting speed and 0.06, 0.08 and [Formula: see text] feed rate). Experimental parameters were designed according to full factorial design method and the results were analyzed using Taguchi L18 experimental design. The results of the study show that the lowest surface roughness values are 0.1958 and [Formula: see text]m with the cutting speed of 90 [Formula: see text] and feed rate of [Formula: see text] in the Point angles of [Formula: see text] and [Formula: see text], respectively. When the results of Anova analysis were evaluated, parameters (feed speed, cutting speed and end point angle) according to the effect ratios on surface roughness were formed at the rates of 41.06%, 33.13% and 5.07%, respectively. The most suitable parameters according to S/N ratios were determined using A2B3C1 factors for the average surface roughness.

Optimization Method of Rotational Axis Motion in 5-Axis Controlled Machining to Keep Command Tool Feed Rate

2020 ◽  
Author(s):  
Takayuki Nakamura ◽  
Kohei Ichikawa ◽  
Masanobu Hasegawa ◽  
Jun'ichi Kaneko ◽  
Takeyuki Abe
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Machining Process ◽  
Rotational Axis ◽  
Feed Speed ◽  
Machining Processes ◽  
Machining Time ◽  
Machined Surface ◽  
Lead Angle ◽  
Tool Posture

Abstract In recent machining processes, 5-axis controlled machine tool is widely used for machining complicated workpiece shape with curved surface. In such process, to achieve high productivity, planning method of cutting conditions to satisfy both following the commanded tool feed rate in machining process and realization of good surface roughness are required. In conventional study, it is known that lead angle of tool posture against local machined surface influence the surface roughness. Then, common commercial CAM systems have already functioned to avoid interference and control the lead angle in each cutter location. However, in the generated cutter locations by the conventional algorithms, when the tool posture changes rapidly, there is a problem that actual feed rate does not reach the command value and machining time becomes longer than expected. In this paper, we propose the new tool posture correction algorithm. In the proposed method, first, the rotational axis that causes the feed speed rate decline is specified by preliminary experiments. And, the jerk value that is the threshold for the feed speed decline is investigated. After that, for the NC program, the command value of the target axis is modified within a range where interference of cutting tool does not occur, thereby preventing a decline in the actual feed rate. This paper describes an outline of the proposed modification method and the effect of the modification of the target axis positions on the lead angle and the actual feed rate.

scholarly journals Understanding the surface integrity of laser surface engineered tungsten carbide

2021 ◽  
Author(s):  
Kafayat Eniola Hazzan ◽  
Manuela Pacella ◽  
Tian Long See
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Surface Integrity ◽  
Laser Processing ◽  
Crack Formation ◽  
Crack Density ◽  
Surface Damage ◽  
Influential Factors ◽  
Fibre Laser ◽  
Feed Speed

AbstractThe study investigated the effect of fibre laser processing (1060 nm, 240-ns pulse duration) on the surface integrity of tungsten carbide (WC). The induced surface damage ranged from crack formation, porosity, balling, to spherical pores; the severity and presence of each were dependent on the laser parameters selected. The influence of fluence (0.05–0.20 J/cm2), frequency (5–100 kHz), feed speed (250–2500 mm/s) and hatch distance (0.02–0.06 mm) on 2D and 3D surface roughness were analysed using the Taguchi technique. Fluence, frequency, and the interaction effect of these were the most influential factors on the surface integrity; from this a linear model was generated to predict the surface roughness. The model performed best at moderate to medium level of processing with an error between 1 and 10 %. The model failed to predict the material response as accurately at higher fluences with percentage errors between 15 and 36 %. In this study, a crack classification system and crack density variable were introduced to estimate the number of cracks and crack type within a 1-mm2 area size. Statistical analysis of variance (ANOVA) found that fluence (63.49%) and frequency (29.38%) had a significant effect on the crack density independently but not the interaction of both. The crack density was minimised at 0.149 J/cm2 and 52.5 kHz. To the author’s knowledge, for the first time, a quantitative analysis of the crack formation mechanism for brittle materials is proposed (post laser processing).

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