Abstract: Monitoring of tool wear in milling operations is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Although there are numerous statistical models and artificial intelligence techniques available for monitoring the wear of cutting tools, these techniques cannot pin point which cutting edge of the tool, or which insert in the case of indexable tooling, is worn or broken. Currently, the task of monitoring the wear on the tool cutting edges is carried out by the operator who performs a manual inspection, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from lost productivity. The present study is concerned with the development of a flute tracking system to segment signals related to each physical flute of a cutter with three flutes used in an end milling operation. The purpose of the system is to monitor the cutting condition for individual flutes separately in order to determine their progressive wear rates and to predict imminent tool failure. The results of this study clearly show that signals associated with each flute can be effectively segmented using the proposed flute tracking system. Furthermore, the results illustrate that by segmenting the sensor signal by flutes it is possible to investigate the wear in each physical cutting edge of the cutting tool. These findings are significant in that they facilitate the online condition monitoring of a cutting tool for each specific flute without the need for operators/engineers to perform manual inspections of the tool.
Abstract: Wire Electric Discharge Machining (WEDM) is
thermal machining process capable of machining very hard
electrically conductive material irrespective of their hardness.
WEDM is being widely used to machine micro scale parts with the
high dimensional accuracy and surface finish. The objective of this
paper is to optimize the process parameters of wire EDM to fabricate
the micro channels and to calculate the surface finish and material
removal rate of micro channels fabricated using wire EDM. The
material used is aluminum 6061 alloy. The experiments were
performed using CNC wire cut electric discharge machine. The effect
of various parameters of WEDM like pulse on time (TON) with the
levels (100, 150, 200), pulse off time (TOFF) with the levels (25, 35,
45) and current (IP) with the levels (105, 110, 115) were investigated
to study the effect on output parameter i.e. Surface Roughness and
Material Removal Rate (MRR). Each experiment was conducted
under different conditions of pulse on time, pulse off time and peak
current. For material removal rate, TON and Ip
were the most significant process parameter. MRR increases with the increase in
TON and Ip and decreases with the increase in TOFF. For surface
roughness, TON and Ip have the maximum effect and TOFF was found
out to be less effective.
Abstract: The use of titanium fluoride and iron fluoride
(TiF3/FeF3) catalysts in combination with polutetrafluoroethylene
(PTFE) in plain zinc- dialkyldithiophosphate (ZDDP) oil is important
for the study of engine tribocomponents and is increasingly a strategy
to improve the formation of tribofilm and provide low friction and
excellent wear protection in reduced phosphorus plain ZDDP oil. The
influence of surface roughness and the concentration of
TiF3/FeF3/PTFE were investigated using bearing steel samples
dipped in lubricant solution at 100°C for two different heating time
durations. This paper addresses the effects of water drop contact
angle using different surface; finishes after treating them with
different lubricant combination. The calculated water drop contact
angles were analyzed using Design of Experiment software (DOE)
and it was determined that a 0.05 μm Ra surface roughness would
provide an excellent TiF3/FeF3/PTFE coating for antiwear resistance
as reflected in the Scanning electron microscopy (SEM) images and
the tribological testing under extreme pressure conditions. Both
friction and wear performance depend greatly on the PTFE/and
catalysts in plain ZDDP oil with 0.05 % phosphorous and on the
surface finish of bearing steel. The friction and wear reducing effects,
which was observed in the tribological tests, indicated a better micro
lubrication effect of the 0.05 μm Ra surface roughness treated at
100°C for 24 hours when compared to the 0.1 μm Ra surface
roughness with the same treatment.
Abstract: In this study, ultrasonic assisted machining (UAM) technique is applied in side-surface milling experiment for glass-ceramic workpiece material. The tungsten carbide cutting-tool with diamond coating is used in conjunction with two kinds of cooling/lubrication mediums such as water-soluble (WS) cutting fluid and minimum quantity lubricant (MQL). Full factorial process parameter combinations on the milling experiments are planned to investigate the effect of process parameters on cutting performance. From the experimental results, it tries to search for the better process parameter combination which the edge-indentation and the surface roughness are acceptable. In the machining experiments, ultrasonic oscillator was used to excite a cutting-tool along the radial direction producing a very small amplitude of vibration frequency of 20KHz to assist the machining process. After processing, toolmaker microscope was used to detect the side-surface morphology, edge-indentation and cutting tool wear under different combination of cutting parameters, and analysis and discussion were also conducted for experimental results. The results show that the main leading parameters to edge-indentation of glass ceramic are cutting depth and feed rate. In order to reduce edge-indentation, it needs to use lower cutting depth and feed rate. Water-soluble cutting fluid provides a better cooling effect in the primary cutting area; it may effectively reduce the edge-indentation and improve the surface morphology of the glass ceramic. The use of ultrasonic assisted technique can effectively enhance the surface finish cleanness and reduce cutting tool wear and edge-indentation.
Abstract: This paper presents a study the effect of nose radius
(Rz-mm) on cutting force components and temperatures during the
machining simulation in an orthogonal cutting process for titanium
alloy (Ti-6Al-4V). The cutting process was performed at various
nose radiuses (Rz-mm) while the depth of cut (d-mm), feed rate (fmm/
tooth) and cutting speed (vc-m/ min) were remained constant.
The main cutting force (Fc), feed cutting force (Ft) and temperatures
were estimated by using finite element modeling (FEM) through
ABAQUS/EXPLICIT software and the simulation was developed the
two-dimension via an orthogonal cutting process during machining
titanium alloy (Ti-6Al-4V). The results led to the conclusion that the
nose radius (Rz-mm) has affected directly on the cutting force
components. However, temperature gave no indication or has no
significant relation with nose radius during machining titanium alloy
(Ti-6Al-4V). Hence, any increase or decrease in the nose radius (Rzmm)
during machining operation led to effect on the cutting forces
and thus it will be effective on surface finish, quality, and quantity of
products.
Abstract: The capability of CNC gantry milling machines in
manufacturing long components has caused the expanded use of such
machines. On the other hand, the machines’ gantry rigidity can
reduce under severe loads or vibration during operation. Indeed, the
quality of machining is dependent on the machine’s dynamic
behavior throughout the operating process. For this reason, these
types of machines have always been used widely and are not
efficient. Therefore, they can usually be employed for rough
machining and may not produce adequate surface finishing. In this
paper, a CNC gantry milling machine with the potential to produce
good surface finish has been designed and analyzed. The lowest
natural frequency of this machine is 202 Hz corresponding to 12000
rpm at all motion amplitudes with a full range of suitable frequency
responses. Meanwhile, the maximum deformation under dead loads
for the gantry machine is 0.565*m, indicating that this machine tool
is capable of producing higher product quality.
Abstract: Vancron 40, a nitrided powder metallurgical tool
Steel, is used in cold work applications where the predominant failure
mechanisms are adhesive wear or galling. Typical applications of
Vancron 40 are among others fine blanking, cold extrusion, deep
drawing and cold work rolls for cluster mills. Vancron 40 positive
results for cold work rolls for cluster mills and as a tool for some
severe metal forming process makes it competitive compared to other
type of work rolls that require higher precision, among others in cold
rolling of thin stainless steel, which required high surface finish
quality. In this project, three roll materials for cold rolling of stainless
steel strip was examined, Vancron 40, Narva 12B (a high-carbon,
high-chromium tool steel alloyed with tungsten) and Supra 3 (a
Chromium-molybdenum tungsten-vanadium alloyed high speed
steel). The purpose of this project was to study the depth profiles of
the ironed stainless steel strips, emergence of galling and to study the
lubrication performance used by steel industries. Laboratory
experiments were conducted to examine scratch of the strip, galling
and surface roughness of the roll materials under severe tribological
conditions. The critical sliding length for onset of galling was
estimated for stainless steel with four different lubricants. Laboratory
experiments result of performance evaluation of resistance capability
of rolls toward adhesive wear under severe conditions for low and
high reductions. Vancron 40 in combination with cold rolling
lubricant gave good surface quality, prevents galling of
metal surfaces and good bearing capacity.
Abstract: This paper reveals the interaction between hydrogen
and surface stress in austenitic stainless steel by X-ray diffraction
stress measurement and thermal desorption analysis before and after
being charged with hydrogen. The surface residual stress was varied
by surface finishing using several disc polishing agents. The obtained
results show that the residual stress near surface had a significant
effect on hydrogen absorption behavior, that is, tensile residual stress
promoted the hydrogen absorption and compressive one did opposite.
Also, hydrogen induced equi-biaxial stress and this stress has a linear
correlation with hydrogen content.
Abstract: This paper presents the findings of an experimental investigation of important machining parameters for the horizontal boring tool modified to mouth with a horizontal lathe machine to bore an overlength workpiece. In order to verify a usability of a modified tool, design of experiment based on Taguchi method is performed. The parameters investigated are spindle speed, feed rate, depth of cut and length of workpiece. Taguchi L9 orthogonal array is selected for four factors three level parameters in order to minimize surface roughness (Ra and Rz) of S45C steel tubes. Signal to noise ratio analysis and analysis of variance (ANOVA) is performed to study an effect of said parameters and to optimize the machine setting for best surface finish. The controlled factors with most effect are depth of cut, spindle speed, length of workpiece, and feed rate in order. The confirmation test is performed to test the optimal setting obtained from Taguchi method and the result is satisfactory.
Abstract: In this study, Electrical Discharge Machining (EDM) is used to modify the surface of high carbon steel En31 with the help of tool electrode (Copper-Chromium-Nickel) manufactured by powder metallurgy (PM) process. The effect of EDM on surface roughness during surface alloying is studied. Taguchi’s Design of experiment (DOE) and L18 orthogonal array is used to find the best level of input parameters in order to achieve high surface finish. Six input parameters are considered and their percentage contribution towards surface roughness is investigated by analysis of variances (ANOVA). Experimental results show that an hard alloyed surface (1.21% carbon, 2.14% chromium and 1.38% nickel) with surface roughness of 3.19µm can be generated using EDM with PM tool. Additionally, techniques like Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) are used to analyze the machined surface and EDMed layer composition, respectively. The increase in machined surface micro-hardness (101%) may be related to the formation of carbides containing chromium.
Abstract: A study on grindability of chopped strand mat glass fiber reinforced polymer laminates (CSM GFRP) have been carried out to evaluate the significant parameters on wheel performance. Performance of Aluminum oxide and c-BN wheels during grinding of CSM GFRP laminate was evaluated in terms of grinding force and surface roughness during grinding. The cubic Boron Nitride wheel experiences higher tangential grinding forces components and lower normal force component than Aluminum oxide grinding wheels. In case of surface finish, Aluminum oxide grinding wheels outdo the cubic Boron Nitride grinding wheels.
Abstract: G-code is the main factor in computer numerical control (CNC) machine for controlling the toolpaths and generating the profile of the object’s features. For obtaining high surface accuracy of the surface finish, non-stop operation is required for CNC machine. Recently, to design a new product, the strategy that concerns about a change that has low impact on business and does not consume lot of resources has been introduced. Cost and time for designing minor changes can be reduced since the traditional geometric details of the existing models are applied. In order to support this strategy as the alternative channel for machining operation, this research proposes the automatic generating codes for CNC milling operation. Using this technique can assist the manufacturer to easily change the size and the geometric shape of the product during the operation where the time spent for setting up or processing the machine are reduced. The algorithm implemented on MATLAB platform is developed by analyzing and evaluating the geometric information of the part. Codes are created rapidly to control the operations of the machine. Comparing to the codes obtained from CAM, this developed algorithm can shortly generate and simulate the cutting profile of the part.
Abstract: Grinding requires high specific energy and the consequent development of high temperature at tool-workpiece contact zone impairs workpiece quality by inducing thermal damage to the surface. Finishing grinding process requires component to be cut more than one pass. This paper deals with an investigation on the effect of multipass cutting on grinding performance in term of surface roughness and surface defect. An experimental set-up has been developed for this and a detailed comparison has been done with a single pass and various numbers of cutting pass. Results showed that surface roughness increase with the increase in a number of cutting pass. Good surface finish of 0.26μm was obtained for single pass cutting and 0.73μm for twenty pass cutting. It was also observed that the thickness of the white layer increased with the increased in a number of cutting pass.
Abstract: Electrical discharge machining (EDM) is a relatively modern machining process having distinct advantages over other machining processes and can machine Ti-alloys effectively. The present study emphasizes the features of the development of regression equation based on response surface methodology (RSM) for correlating the interactive and higher-order influences of machining parameters on surface finish of Titanium alloy Ti-6Al-4V. The process parameters selected in this study are discharge current, pulse on time, pulse off time and servo voltage. Machining has been accomplished using negative polarity of Graphite electrode. Analysis of variance is employed to ascertain the adequacy of the developed regression model. Experiments based on central composite of response surface method are carried out. Scanning electron microscopy (SEM) analysis was performed to investigate the surface topography of the EDMed job. The results evidence that the proposed regression equation can predict the surface roughness effectively. The lower ampere and short pulse on time yield better surface finish.
Abstract: Present investigations involve a systematic study on the machinability of austempered ductile irons (ADI) developed from four commercially viable ductile irons alloyed with different contents of 0, 0.1, 0.3 and 0.6 wt.% of Ni. The influence of Ni content, amount of retained austenite and hardness of ADI on machining behavior has been conducted systematically. Austempering heat treatment was carried out for 120 minutes at four temperatures- 270oC, 320oC, 370oC or 420oC, after austenitization at 900oC for 120 min. Milling tests were performed and machinability index, cutting forces and surface roughness measurements were used to evaluate the machinability. Higher cutting forces, lower machinability index and the poorer surface roughness of the samples austempered at lower temperatures indicated that austempering at higher temperatures resulted in better machinability. The machinability of samples austempered at 420oC, which contained higher fractions of retained austenite, was superior to that of samples austempered at lower temperatures, indicating that hardness is an important factor in assessing machinability in addition to high carbon austenite content. The ADI with 0.6% Ni, austempered at 420°C for 120 minutes, demonstrated best machinability.
Abstract: The suitability of Newsprint and Kraft papers for the production of cement bonded ceiling board was investigated. Sample boards were produced from newsprint paper (100%), mixture of newsprint and Kraft paper (50:50) and Kraft paper (100%) at 1:1, 2:1 and 3:1 cement/paper mixing ratio respectively with 3% additive concentration of calcium chloride (CaCl2). Density, flexural and thickness swelling properties of the boards were investigated. The effects of paper type and mixing ratio on the physical and mechanical properties were also examined. The bending properties of the board which include Modulus of Elasticity (MOE) and Modulus of Rupture (MOR) increased linearly with increase in density. Modulus of rupture of boards increased as the density and mixing ratio increased. The thickness swelling property for the two paper types decreased as the board density and mixing ratio increased. Boards made from Kraft paper recorded higher strength values than the ones made from recycled newsprint paper while the mixture of kraft and newsprint papers had the best surface finish. The result of the study will help in managing the large quality of waste from paper converting/carton industry and that the ceiling boards produced could be installed with clout nails or used with suspended ceiling fittings.
Abstract: The functional performance of machined components, often, depends on surface topography, hardness, nature of stress and strain induced on the surface, etc. Invariably, surfaces of metallic components obtained by turning, milling, etc., consist of irregularities such as machining marks are responsible for the above. Surface finishing/coating processes used to produce improved surface quality/textures are classified as chip-removal and chip-less processes. Burnishing is chip-less cold working process carried out to improve surface finish, hardness and resistance to fatigue and corrosion; not obtainable by other surface coating and surface treatment processes. It is a very simple, but effective method which improves surface characteristics and is reported to introduce compressive stresses.
Of late, considerable attention is paid to post-machining, finishing operations, such as burnishing. During burnishing the micro-irregularities start to deform plastically, initially the crests are gradually flattened and zones of reduced deformation are formed. When all the crests are deformed, the valleys between the micro-irregularities start moving in the direction of the newly formed surface. The grain structure is then condensed, producing a smoother and harder surface with superior load-carrying and wear-resistant capabilities.
Burnishing can be performed on a lathe with a highly polished ball or roller type tool which is traversed under force over a rotating/stationary work piece. Often, several passes are used to obtain the work piece surface with the desired finish and hardness.
This paper presents the findings of an experimental investigation on the effect of ball burnishing parameters such as, burnishing speed, feed, force and number of passes; on surface roughness (Ra) and micro-hardness (Hv) of a 60/40 copper/zinc alloy, using a 2-level fractional factorial design of experiments (DoE). Mathematical models were developed to predict surface roughness and hardness generated by burnishing in terms of the above process parameters. A ball-type tool, designed and constructed from a high chrome steel material (HRC=63 and Ra=0.012 µm), was used for burnishing of fine-turned cylindrical bars (0.68-0.78µm and 145Hv). They are given by,
Ra= 0.305-0.005X1 - 0.0175X2 + 0.0525X4 + 0.0125X1X4 -0.02X2X4 - 0.0375X3X4
Hv=160.625 -2.37 5X1 + 5.125X2 + 1.875X3 + 4.375X4 - 1.625X1X4 + 4.375X2X4 - 2.375X3X4
High surface microhardness (175HV) was obtained at 400rpm, 2passes, 0.05mm/rev and 15kgf., and high surface finish (0.20µm) was achieved at 30kgf, 0.1mm/rev, 112rpm and single pass. In other words, surface finish improved by 350% and microhardness improved by 21% compared to as machined conditions.
Abstract: Abrasive Water Jet Machining is an unconventional machining process well known for machining hard to cut materials. The primary research focus on the process was for through cutting and a very limited literature is available on pocket milling using AWJM. The present work is an attempt to use this process for milling applications considering a set of various process parameters. Four different input parameters, which were considered by researchers for part separation, are selected for the above application, i.e., abrasive size, flow rate, standoff distance and traverse speed. Pockets of definite size are machined to investigate surface roughness, material removal rate and pocket depth. Based on the data available through experiments on SS304 material, it is observed that higher traverse speeds gives a better finish because of reduction in the particle energy density and lower depth is also observed. Increase in the standoff distance and abrasive flow rate reduces the rate of material removal as the jet loses its focus and occurrence of collisions within the particles. ANOVA for individual output parameter has been studied to know the significant process parameters.
Abstract: This paper presents a comparative study on dry and wet grinding through experimental investigation in the grinding of CSM glass fibre reinforced polymer laminates using a pink aluminium oxide wheel. Different sets of experiments were performed to study the effects of the independent grinding parameters such as grinding wheel speed, feed and depth of cut on dependent performance criteria such as cutting forces and surface finish. Experimental conditions were laid out using design of experiment central composite design. An effective coolant was sought in this study to minimise cutting forces and surface roughness for GFRP laminates grinding. Test results showed that the use of coolants reduces surface roughness, although not necessarily the cutting forces. These research findings provide useful economic machining solution in terms of optimized grinding conditions for grinding CSM GFRP.
Abstract: This paper describes a rapid prototyping (RP)
technology for forming a hydroxyapatite (HA) bone scaffold model.
The HA powder and a silica sol are mixed into bioceramic slurry form
under a suitable viscosity. The HA particles are embedded in the
solidified silica matrix to form green parts via a wide range of process
parameters after processing by selective laser sintering (SLS). The
results indicate that the proposed process was possible to fabricate
multilayers and hollow shell structure with brittle property but
sufficient integrity for handling prior to post-processing. The
fabricated bone scaffold models had a surface finish of 25