Abstract: Inconel 718, a nickel based super-alloy is an
extensively used alloy, accounting for about 50% by weight of
materials used in an aerospace engine, mainly in the gas turbine
compartment. This is owing to their outstanding strength and
oxidation resistance at elevated temperatures in excess of 5500 C.
Machining is a requisite operation in the aircraft industries for the
manufacture of the components especially for gas turbines. This
paper is concerned with optimization of the surface roughness when
turning Inconel 718 with cermet inserts. Optimization of turning
operation is very useful to reduce cost and time for machining. The
approach is based on Response Surface Method (RSM). In this work,
second-order quadratic models are developed for surface roughness,
considering the cutting speed, feed rate and depth of cut as the cutting
parameters, using central composite design. The developed models
are used to determine the optimum machining parameters. These
optimized machining parameters are validated experimentally, and it
is observed that the response values are in reasonable agreement with
the predicted values.
Abstract: Drilling is the most common machining operation and it forms the highest machining cost in many manufacturing activities including automotive engine production. The outcome of this operation depends upon many factors including utilization of proper cutting tool geometry, cutting tool material and the type of coating used to improve hardness and resistance to wear, and also cutting parameters. With the availability of a large array of tool geometries, materials and coatings, is has become a challenging task to select the best tool and cutting parameters that would result in the lowest machining cost or highest profit rate. This paper describes an algorithm developed to help achieve good performances in drilling operations by automatically determination of proper cutting tools and cutting parameters. It also helps determine machining sequences resulting in minimum tool changes that would eventually reduce machining time and cost where multiple tools are used.
Abstract: Machining through turning was carried out in a lathe
to study the chip formation of Multiphase Ferrite
(F-B-M) microalloyed steel. Taguchi orthogonal array was employed
to perform the machining. Continuous and discontinuous chips were
formed for different cutting parameters like speed, feed and depth of
cut. Optical and scanning electron microscope was employed to
identify the chip morphology.
Abstract: The aim of this research is to evaluate surface
roughness and develop a multiple regression model for surface roughness as a function of cutting parameters during the turning of
flame hardened medium carbon steel with TiN-Al2O3-TiCN coated inserts. An experimental plan of work and signal-to-noise ratio (S/N)
were used to relate the influence of turning parameters to the
workpiece surface finish utilizing Taguchi methodology. The effects
of turning parameters were studied by using the analysis of variance (ANOVA) method. Evaluated parameters were feed, cutting speed,
and depth of cut. It was found that the most significant interaction among the considered turning parameters was between depth of cut and feed. The average surface roughness (Ra) resulted by TiN-Al2O3-
TiCN coated inserts was about 2.44 μm and minimum value was 0.74 μm. In addition, the regression model was able to predict values for surface roughness in comparison with experimental values within
reasonable limit.
Abstract: End milling process is one of the common metal
cutting operations used for machining parts in manufacturing
industry. It is usually performed at the final stage in manufacturing a
product and surface roughness of the produced job plays an
important role. In general, the surface roughness affects wear
resistance, ductility, tensile, fatigue strength, etc., for machined parts
and cannot be neglected in design. In the present work an
experimental investigation of end milling of aluminium alloy with
carbide tool is carried out and the effect of different cutting
parameters on the response are studied with three-dimensional
surface plots. An artificial neural network (ANN) is used to establish
the relationship between the surface roughness and the input cutting
parameters (i.e., spindle speed, feed, and depth of cut). The Matlab
ANN toolbox works on feed forward back propagation algorithm is
used for modeling purpose. 3-12-1 network structure having
minimum average prediction error found as best network architecture
for predicting surface roughness value. The network predicts surface
roughness for unseen data and found that the result/prediction is
better. For desired surface finish of the component to be produced
there are many different combination of cutting parameters are
available. The optimum cutting parameter for obtaining desired
surface finish, to maximize tool life is predicted. The methodology is
demonstrated, number of problems are solved and algorithm is coded
in Matlab®.
Abstract: The quality of a machined surface is becoming more and more important to justify the increasing demands of sophisticated component performance, longevity, and reliability. Usually, any machining operation leaves its own characteristic evidence on the machined surface in the form of finely spaced micro irregularities (surface roughness) left by the associated indeterministic characteristics of the different elements of the system: tool-machineworkpart- cutting parameters. However, one of the most influential sources in machining affecting surface roughness is the instantaneous state of tool edge. The main objective of the current work is to relate the in-process immeasurable cutting edge deformation and surface roughness to a more reliable easy-to-measure force signals using a robust non-linear time-dependent modeling regression techniques. Time-dependent modeling is beneficial when modern machining systems, such as adaptive control techniques are considered, where the state of the machined surface and the health of the cutting edge are monitored, assessed and controlled online using realtime information provided by the variability encountered in the measured force signals. Correlation between wear propagation and roughness variation is developed throughout the different edge lifetimes. The surface roughness is further evaluated in the light of the variation in both the static and the dynamic force signals. Consistent correlation is found between surface roughness variation and tool wear progress within its initial and constant regions. At the first few seconds of cutting, expected and well known trend of the effect of the cutting parameters is observed. Surface roughness is positively influenced by the level of the feed rate and negatively by the cutting speed. As cutting continues, roughness is affected, to different extents, by the rather localized wear modes either on the tool nose or on its flank areas. Moreover, it seems that roughness varies as wear attitude transfers from one mode to another and, in general, it is shown that it is improved as wear increases but with possible corresponding workpart dimensional inaccuracy. The dynamic force signals are found reasonably sensitive to simulate either the progressive or the random modes of tool edge deformation. While the frictional force components, feeding and radial, are found informative regarding progressive wear modes, the vertical (power) components is found more representative carrier to system instability resulting from the edge-s random deformation.
Abstract: This paper proposes a method to vibration analysis in
order to on-line monitoring and predictive maintenance during the
milling process. Adapting envelope method to diagnostics and the
analysis for milling tool materials is an important contribution to the
qualitative and quantitative characterization of milling capacity and a
step by modeling the three-dimensional cutting process. An
experimental protocol was designed and developed for the
acquisition, processing and analyzing three-dimensional signal. The
vibration envelope analysis is proposed to detect the cutting capacity
of the tool with the optimization application of cutting parameters.
The research is focused on Hilbert transform optimization to evaluate
the dynamic behavior of the machine/ tool/workpiece.
Abstract: Surface roughness (Ra) is one of the most important requirements in machining process. In order to obtain better surface roughness, the proper setting of cutting parameters is crucial before the process take place. This research presents the development of mathematical model for surface roughness prediction before milling process in order to evaluate the fitness of machining parameters; spindle speed, feed rate and depth of cut. 84 samples were run in this study by using FANUC CNC Milling α-Τ14ιE. Those samples were randomly divided into two data sets- the training sets (m=60) and testing sets(m=24). ANOVA analysis showed that at least one of the population regression coefficients was not zero. Multiple Regression Method was used to determine the correlation between a criterion variable and a combination of predictor variables. It was established that the surface roughness is most influenced by the feed rate. By using Multiple Regression Method equation, the average percentage deviation of the testing set was 9.8% and 9.7% for training data set. This showed that the statistical model could predict the surface roughness with about 90.2% accuracy of the testing data set and 90.3% accuracy of the training data set.
Abstract: Tool wear and surface roughness prediction plays a
significant role in machining industry for proper planning and control
of machining parameters and optimization of cutting conditions. This
paper deals with developing an artificial neural network (ANN)
model as a function of cutting parameters in turning steel under
minimum quantity lubrication (MQL). A feed-forward
backpropagation network with twenty five hidden neurons has been
selected as the optimum network. The co-efficient of determination
(R2) between model predictions and experimental values are 0.9915,
0.9906, 0.9761 and 0.9627 in terms of VB, VM, VS and Ra
respectively. The results imply that the model can be used easily to
forecast tool wear and surface roughness in response to cutting
parameters.
Abstract: Reliable information about tool temperature
distribution is of central importance in metal cutting. In this study,
tool-chip interface temperature was determined in cutting of ST37
steel workpiece by applying HSS as the cutting tool in dry turning.
Two different approaches were implemented for temperature
measuring: an embedded thermocouple (RTD) in to the cutting tool
and infrared (IR) camera. Comparisons are made between
experimental data and results of MSC.SuperForm and FLUENT
software.
An investigation of heat generation in cutting tool was performed
by varying cutting parameters at the stable cutting tool geometry and
results were saved in a computer; then the diagrams of tool
temperature vs. various cutting parameters were obtained. The
experimental results reveal that the main factors of the increasing
cutting temperature are cutting speed (V ), feed rate ( S ) and depth
of cut ( h ), respectively. It was also determined that simultaneously
change in cutting speed and feed rate has the maximum effect on
increasing cutting temperature.
Abstract: The importance of machining process in today-s
industry requires the establishment of more practical approaches to
clearly represent the intimate and severe contact on the tool-chipworkpiece
interfaces. Mathematical models are developed using the
measured force signals to relate each of the tool-chip friction
components on the rake face to the operating cutting parameters in
rough turning operation using multilayers coated carbide inserts.
Nonlinear modeling proved to have high capability to detect the
nonlinear functional variability embedded in the experimental data.
While feedrate is found to be the most influential parameter on the
friction coefficient and its related force components, both cutting
speed and depth of cut are found to have slight influence. Greater
deformed chip thickness is found to lower the value of friction
coefficient as the sliding length on the tool-chip interface is reduced.