Abstract: This study investigates the effects of the lead angle
and chip thickness variation on surface roughness during the
machining of compacted graphite iron using ceramic cutting tools
under dry cutting conditions. Analytical models were developed for
predicting the surface roughness values of the specimens after the
face milling process. Experimental data was collected and imported
to the artificial neural network model. A multilayer perceptron model
was used with the back propagation algorithm employing the input
parameters of lead angle, cutting speed and feed rate in connection
with chip thickness. Furthermore, analysis of variance was employed
to determine the effects of the cutting parameters on surface
roughness. Artificial neural network and regression analysis were
used to predict surface roughness. The values thus predicted were
compared with the collected experimental data, and the
corresponding percentage error was computed. Analysis results
revealed that the lead angle is the dominant factor affecting surface
roughness. Experimental results indicated an improvement in the
surface roughness value with decreasing lead angle value from 88° to
45°.
Abstract: Metal matrix composites (MMCs) attract considerable
attention as a result from its ability in providing a high strength, high
modulus, high toughness, high impact properties, improving wear
resistance and providing good corrosion resistance compared to
unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been
widely used in various industrial sectors such as in transportation,
domestic equipment, aerospace, military, construction, etc.
Aluminium silicon alloy is an MMC that had been reinforced with
aluminium nitrate (AlN) particle and become a new generation
material use in automotive and aerospace sector. The AlN is one of
the advance material that have a bright prospect in future since it has
features such as lightweight, high strength, high hardness and
stiffness quality. However, the high degree of ceramic particle
reinforcement and the irregular nature of the particles along the
matrix material that contribute to its low density is the main problem
which leads to difficulties in machining process. This paper examined
the tool wear when milling AlSi/AlN Metal Matrix Composite using
a TiB2 (Titanium diboride) coated carbide cutting tool. The volume
of the AlN reinforced particle was 10% and milling process was
carried out under dry cutting condition. The TiB2 coated carbide
insert parameters used were at the cutting speed of (230, 300 and
370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The
Sometech SV-35 video microscope system used to quantify of the
tool wear. The result shown that tool life span increasing with the
cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at
0.4mm) which constituted an optimum condition for longer tool life
lasted until 123.2 mins. Meanwhile, at medium cutting speed which
at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we
found that tool life span lasted until 119.86 mins while at low cutting
speed it lasted in 119.66 mins. High cutting speed will give the best
parameter in cutting AlSi/AlN MMCs material. The result will help
manufacturers in machining process of AlSi/AlN MMCs materials.
Abstract: This study presents a new method for detecting the
cutting tool wear based on the measured cutting force signals using
the regression model and I-kaz method. The detection of tool wear
was done automatically using the in-house developed regression
model and 3D graphic presentation of I-kaz 3D coefficient during
machining process. The machining tests were carried out on a CNC
turning machine Colchester Master Tornado T4 in dry cutting
condition, and Kistler 9255B dynamometer was used to measure the
cutting force signals, which then stored and displayed in the DasyLab
software. The progression of the cutting tool flank wear land (VB)
was indicated by the amount of the cutting force generated. Later, the
I-kaz was used to analyze all the cutting force signals from beginning
of the cut until the rejection stage of the cutting tool. Results of the IKaz
analysis were represented by various characteristic of I-kaz 3D
coefficient and 3D graphic presentation. The I-kaz 3D coefficient
number decreases when the tool wear increases. This method can be
used for real time tool wear monitoring.
Abstract: In present work, prediction the effect of nose radius, rz (mm) on the equivalent strain (PEEQ) and surface finish during the machining of titanium alloy (Ti-6Al-4V) through orthogonal cutting process. The results were performed at several of the nose radiuses, rz (mm) while the cutting speed, vc (m/min), feed rate, f (mm/tooth) and depth of cut, d (mm) were remained constant. The equivalent plastic strain (PEEQ) was estimated by using finite element modeling (FEM) and applied through ABAQUS/EXPLICIT software. The simulation results led to conclude that the equivalent plastic strain (PEEQ) was increased and surface roughness (Ra) decreased when increasing nose radius, rz (mm) during the machining of titanium alloy (Ti–6Al–4V) in dry cutting conditions.
Abstract: Cutting fluids, usually in the form of a liquid, are
applied to the chip formation zone in order to improve the cutting
conditions. Cutting fluid can be expensive and represents a biological
and environmental hazard that requires proper recycling and
disposal, thus adding to the cost of the machining operation. For
these reasons dry cutting or dry machining has become an
increasingly important approach; in dry machining no coolant or
lubricant is used. This paper discussed the effect of the dry cutting on
cutting force and tool life when machining aerospace materials
(Haynes 242) with using two different coated carbide cutting tools
(TiAlN and TiN/MT-TiCN/TiN). Response surface method (RSM)
was used to minimize the number of experiments. ParTiAlN Swarm
Optimisation (PSO) models were developed to optimize the
machining parameters (cutting speed, federate and axial depth) and
obtain the optimum cutting force and tool life. It observed that
carbide cutting tool coated with TiAlN performed better in dry
cutting compared with TiN/MT-TiCN/TiN. On other hand, TiAlN
performed more superior with using of 100 % water soluble coolant.
Due to the high temperature produced by aerospace materials, the
cutting tool still required lubricant to sustain the heat transfer from
the workpiece.