Effect of Tool Nose Radius and Machining Parameters on Cutting Force, Cutting Temperature and Surface Roughness – An Experimental Study of Ti-6Al-4V (ELI) (original) (raw)
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2013
This research work focuses on precision turning of Ti6Al4V material to investigate the machinability of the material. Precision turning is a type of machining where, very low feed rate and depth of cut is being used to machine using a cutting insert with a lower nose radius. The cutting parameters considered for the experiments include the cutting speed, feed rate, depth of cut and nose radius. PVD coated carbide cutting inserts with different nose radius and constant rake and clearance angle are being considered for experimentation. The experimentation was designed based on Taguchi's L 27 orthogonal array. Three different levels of cutting parameters were being considered for the experimentation. The turning experiments were carried out on a conventional variable speed motor lathe under dry working conditions. Based upon the experimental values, Analysis of Variance (ANOVA) was conducted to understand the influence of various cutting parameters on cutting force, surface roughness chip morphology, tool wear and cutting tool temperatures during precision turning of titanium alloy. Optimal levels of parameters were identified using grey relational analysis and significant parameter was determined by analysis of variance. Experimental results indicate that multi-response characteristics.
Study and Analysis of Effect of Cutting Parameters on Cutting Forces and Surface Roughness
2015
In the present competitive and dynamic market environment, large and small manufacturing industries are more allotted to Optimization and economic machining. Cutting parameters play a crucial role in every machining process in affecting the production rate, quality of the output and economical aspects of a machining process. Finite element simulation of the cutting process is advantageous in many ways over experimental analysis, as it provides information on deformations along each point of cutting line, stresses induced at each node/point and temperature distribution in the tool and work material during the machining process. In this paper, the significant effect of cutting speed, feed rate and rake angle on cutting forces, tool temperature and work specimen temperature in machining AISI 1045 mild carbon steel has been studied. For the study of which, a series of 20 experiments and simulation trials were conducted as per design of experiments. All the other parameters besides the s...
Zenodo (CERN European Organization for Nuclear Research), 2022
In this paper, the influence of four factors on the forces during cutting, especially on the friction force was investigated. These factors are water quantity in MQL, speed, depth, and feed rate. In this study, the optimization of those factors to find their optimal combination for obtaining minimal intensity friction force has been looked into. The null hypothesis is that by using the MQL technique, the friction force can be significantly reduced. The experiment was planned using Taguchi's L9 design of experiments. The study included performing the machining of the workpiece through different combinations of levels for the spindle speed, feed rate, amount of water, and depth of cut as the main parameters.
IJETNAS, 2016
Ti6Al4V titanium alloy is widely used in aviation and medical industries due to its high temperature strength and biological compatibility, respectively. Since cutting forces obtained during machining of this material are directly related to cutting temperatures and tool life, determination of these forces has great importance for an economical and sustainable manufacturing. Therefore, in this study, the cutting forces occurring in face milling of Ti6Al4V alloy by carbide cutting tools were measured and the effect of cutting parameters on these forces was investigated. Single layer TiN and TiAlN coatings were deposited on the carbide tools by physical vapor deposition method. In cutting tests, three different cutting speed (50-150 m/min) and feed rate (0.05-0.15 mm/tooth) were used, keeping the depth of cut constant (0.5 mm). According to the results, the TiN coated tools have lower resultant cutting force than the TiAlN coated ones. The resultant cutting force increases with the feed rate at all cutting speeds, while at cutting speed of 50 m/min the maximum resultant cutting force was obtained at feed rate of 0.05 mm/tooth. When the effect of cutting speed was analyzed, it is seen that the resultant cutting force were affected differently for each feed rate values. The minimum resultant cutting force was obtained at cutting speed of 50 m/min and the feed rate of 0.10 mm/tooth with the TiN coated tools, while it was obtained at the feed rate of 0.05 mm/tooth and cutting speeds of 100 and 150 m/min. The influence of the coating material is more dominant at the hardest cutting conditions. Optimal cutting conditions in terms of resultant cutting force were determined as cutting speed of 100 m/min and feed rate of 0.05 mm/tooth using the TiN coated tools.
Examined the correlation between surface roughness and cutting tool vibration for turning operation. The process parameters were cutting speed, depth of cut, feed rate The objective of this paper is to analyze the performance of precision turning using a conventional lathe on Ti6Al4V under dry working conditions. Various parameters that affect the machining processes were identified and a consensus was reached regarding its values. The proposed work is to perform machining under the selected levels of conditions and parameters and to estimate the, cutting temperature and surface roughness generated as the result of the machining process. This paper presents investigations on turning Ti–6Al–4V alloy with multi-layer coated inserts. Turning of Ti–6Al–4V using uncoated, TiAlN coated, and TiAlN + cBN coated single and multi-layer coated tungsten carbide inserts is conducted, cutting temperature and surface roughness are measured. ANOVA is used to find the percentage contribution of each parameter to the surface roughness and cutting temperature.
2013
In this study, we have investigated the effects of different insert radii of cutting tools, different depths of cut and, different feed rates on the surface quality of the workpieces depending on various processing parameters. Properly, the AISI 1030 steel is processed at a digitally controlled computerised numerical control(CNC) turning lathe without using cooling water with three different insert radii (0.4, 0.8, and 1.2 mm) of cemented carbide cutting tools, coated with three layer coating materials (outermost is TiN) applied by the chemical vapour deposition CVD technique. The effects of five different depths of cut (0.5, 1, 1.5, 2, 2.5 mm) and five different feed rates/advancing steps (0.15, 0.2, 0.25, 0.30, 0.35 mm/rev) on the surface roughness values have been investigated by a turning process while from the cutting parameters the cutting speed is kept constant at (300 m/min). It is seen that the insert radius, feed rate, and depth of cut have different effects on the surface roughness. In the experiments, the minimum average surface roughness has been obtained using the cutting tools of maximum insert radius (1.2 mm). The surface roughness have been improved by 293% when the insert radius (0.4 mm) was increased by 200% (1.2 mm). When the feed rate (0.35 mm/rev) was reduced by 133% (0.15 mm/rev), the surface roughness have been improved by 313%, and by reducing the depth of cut (0.5 mm) by 400% (0.25 mm), an amelioration of 23% has been obtained on the surface roughness.
Influence of Cutting Parameters on Cutting Force and Surface Finish in Turning Operation
Procedia Engineering, 2013
This research reports the significance of influence of speed, feed and depth of cut on cutting force and surface roughness while working with tool made of ceramic with an Al 2 O 3 +TiC matrix (KY1615)and the work material of AISI 1050 steel (hardness of 484 HV). Experiments were conducted using Johnford TC35 Industrial type of CNC lathe. Taguchi method (L27 design with 3 levels and 3 factors) was used for the experiments. Analysis of variance with adjusted approach has been adopted. The results have indicated that it is feed rate which has significant influence both on cutting force as well as surface roughness. Depth of cut has a significant influence on cutting force, but has an insignificant influence on surface roughness. The interaction of feed and depth of cut and the interaction of all the three cutting parameters have significant influence on cutting force, whereas, none of the interaction effects are having significant influence on the surface roughness produced. If power consumption minimization is to be achieved for the best possible surface finish, the most recommended combination of feed rate and depth of cut is also determined.
IOP Conference Series: Materials Science and Engineering
Present work deals with prediction of surface roughness using cutting parameters along with in-process measured cutting force and tool vibration (acceleration) during turning of Ti-6Al-4V with cubic boron nitride (CBN) inserts. Full factorial design is used for design of experiments using cutting speed, feed rate and depth of cut as design variables. Prediction model for surface roughness is developed using response surface methodology with cutting speed, feed rate, depth of cut, resultant cutting force and acceleration as control variables. Analysis of variance (ANOVA) is performed to find out significant terms in the model. Insignificant terms are removed after performing statistical test using backward elimination approach. Effect of each control variables on surface roughness is also studied. Correlation coefficient (R 2 pred) of 99.4% shows that model correctly explains the experiment results and it behaves well even when adjustment is made in factors or new factors are added or eliminated. Validation of model is done with five fresh experiments and measured forces and acceleration values. Average absolute error between RSM model and experimental measured surface roughness is found to be 10.2%. Additionally, an artificial neural network model is also developed for prediction of surface roughness. The prediction results of modified regression model are compared with ANN. It is found that RSM model and ANN (average absolute error 7.5%) are predicting roughness with more than 90% accuracy. From the results obtained it is found that including cutting force and vibration for prediction of surface roughness gives better prediction than considering only cutting parameters. Also, ANN gives better prediction over RSM models.
Cutting Parameters and the Machinability Performance
Down Milling Trimming Process Optimization for Carbon Fiber-Reinforced Plastic
Optimizing cutting parameters is very significant to obtain good machined surface and meet engineering specifications. It is also can save energy, reduce waste, save processing time, and increase tool life [1]. Generally, there are four types of cutting parameters normally associated with machining operation, i.e., cutting speed, spindle speed, depth of cut, and feed rate [2-6]. All of these parameters have been identified as the influential factors in determining the surface quality of every machined part. Most of the researchers focused on four cutting parameters during their studies on optimization in composite machining. They are spindle speed, cutting speed, depth of cut, and feed rate [7-9]. In general, the best machined surface quality is being determined by the kind of material being cut, and the size and type of the cutter used, width and depth of cut, method of application, and speed available are factors relating to machinability performance. 2.1.1 Cutting Speed (m/min) The cutting speed expressed in meters per minute (m/min) must not be confused with the spindle speed which is expressed in revolution per minute (rpm). Cutting speed represents the rate of the cutter passed over the surface of the machined part, whereby the spindle speed is obtained by calculating from a selected cutting speed. The cutting speed of a metal may be defined as the speed, in surface feet per minute or linear feet per minute (sf/min or mm/min) that a given tooth (flute) at which the metal may be machined efficiently. When the work is machined on a milling machine, the cutter must be revolved at a specific number of (r/min), depending on its diameter to achieve the proper cutting speed. In workshop practices, the machinist used spindle