Optimization of surface roughness and machining parameters for turning superalloy GH4169 under high-pressure cooling

2021 ◽  
Author(s):  
Yali Zhang ◽  
Mingyang Wu ◽  
Keke Liu ◽  
Jianyu Zhang
Keyword(s):  
Surface Roughness ◽  
High Pressure ◽  
Prediction Model ◽  
Metal Cutting ◽  
Optimal Parameter ◽  
Orthogonal Experiment ◽  
Cutting Speed ◽  
Linear Regression Method ◽  
Machining Parameters ◽  
Cooling Conditions

Abstract Superalloys are important structural materials in the aerospace and petrochemical industries. Because of their excellent fatigue and oxidation resistance, superalloys are usually used predominantly in rotor and turbine components. The requirement of good surface quality and high-precision processes has been widely concerned. High-pressure cooling is a commonly used auxiliary processing technology in the metal cutting field, which can efficiently improve the quality of the processed surface. It is of great significance to study the surface roughness of GH4169 processed by cutting under high-pressure cooling conditions. First, the single-factor and orthogonal experiment methods were used. The single factors, interaction effect, and quadratic effect of cutting parameters and cooling pressure were analyzed. Then, the multiple linear regression method was adopted to establish the prediction model for surface roughness of GH4169, and the accuracy of this model was verified. Finally, according to the prediction model, the machining parameters were optimized and verified. The results indicated that the proposed model was accurate and reliable, which could be used to optimize the machining parameters. The optimal parameter combination was achieved, with the cutting speed of 154 m/min, the feed rate of 0.10 mm/r, the cutting depth of 0.46 mm, and the cooling pressure of 52 bar. Under this parameter setting, the prediction error was 4.20%, and the surface roughness was 34.92% less than that obtained under the actually recommended machining parameters. The above results will provide theoretical guidance for the parameter optimization of cutting superalloy under high-pressure cooling conditions and quality control of the processed surface.

A Prediction Model of Surface Roughness in Micro End Milling

2015 ◽  
Vol 727-728 ◽  
pp. 354-357
Author(s):  
Mei Xia Yuan ◽  
Xi Bin Wang ◽  
Li Jiao ◽  
Yan Li
Keyword(s):  
Surface Roughness ◽  
Prediction Model ◽  
Feed Rate ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Cutting Depth ◽  
Micro End Milling

Micro-milling orthogonal experiment of micro plane was done in mesoscale. Probability statistics and multiple regression principle were used to establish the surface roughness prediction model about cutting speed, feed rate and cutting depth, and the significant test of regression equation was done. On the basis of successfully building the prediction model of surface roughness, the diagram of surface roughness and cutting parameters was intuitively built, and then the effect of the cutting speed, feed rate and cutting depth on the small structure surface roughness was obtained.

scholarly journals Optimal Machining Parameters for Achieving the Desired Surface Roughness in Turning of Steel

2012 ◽  
Vol 9 (1) ◽  
pp. 37 ◽  
Author(s):  
LB Abhang ◽  
M Hameedullah
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Engineering Sciences

 Due to the widespread use of highly automated machine tools in the metal cutting industry, manufacturing requires highly reliable models and methods for the prediction of output performance in the machining process. The prediction of optimal manufacturing conditions for good surface finish and dimensional accuracy plays a very important role in process planning. In the steel turning process the tool geometry and cutting conditions determine the time and cost of production which ultimately affect the quality of the final product. In the present work, experimental investigations have been conducted to determine the effect of the tool geometry (effective tool nose radius) and metal cutting conditions (cutting speed, feed rate and depth of cut) on surface finish during the turning of EN-31 steel. First and second order mathematical models are developed in terms of machining parameters by using the response surface methodology on the basis of the experimental results. The surface roughness prediction model has been optimized to obtain the surface roughness values by using LINGO solver programs. LINGO is a mathematical modeling language which is used in linear and nonlinear optimization to formulate large problems concisely, solve them, and analyze the solution in engineering sciences, operation research etc. The LINGO solver program is global optimization software. It gives minimum values of surface roughness and their respective optimal conditions. 

Design of fuzzy expert system for predicting of surface roughness in high-pressure jet assisted turning using bioinspired algorithms

2015 ◽  
Vol 30 (1) ◽  
pp. 96-106 ◽  
Author(s):  
Davorin Kramar ◽  
Djordje Cica ◽  
Branislav Sredanovic ◽  
Janez Kopac
Keyword(s):  
Surface Roughness ◽  
High Pressure ◽  
Expert System ◽  
Cutting Speed ◽  
Fuzzy Expert System ◽  
Machining Parameters ◽  
Machined Parts ◽  
Roughness Prediction ◽  
Bioinspired Algorithms ◽  
The Impact

AbstractThe surface roughness of the machined parts is one of the most important factors that have considerable influence on the quality and functional properties of products. The objective of this study is development of a surface roughness prediction model for machining Inconel 718 in high-pressure jet assisted turning using the fuzzy expert system, where the fuzzy system is optimized using two bioinspired algorithms: genetic algorithm and particle swarm optimization. The effect of various influential machining parameters, such as diameter of the nozzle, pressure of the jet, cutting speed, feed rate, and distance between the impact point of the jet and cutting edge were taken into consideration in this study. The predicted surface roughness values obtained from developed fuzzy expert systems were compared with the experimental data, and the results indicate that proposed systems can be effectively used to estimate the surface roughness in high-pressure jet assisted turning.

Optimization of machining parameters using WASPAS and MOORA

2019 ◽  
Vol 17 (2) ◽  
pp. 237-246 ◽  
Author(s):  
Venkateshwar Reddy Pathapalli ◽  
Veerabhadra Reddy Basam ◽  
Suresh Kumar Gudimetta ◽  
Madhava Reddy Koppula
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Metal Cutting ◽  
Optimal Parameter ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Content Type ◽  
Composite Samples

Purpose Nowadays, the applications of metal matrix composites are tremendously increasing in engineering fields. Consequently, the demand for precise machining of composites has also grown enormously. The purpose of this paper is to reduce production cost and simultaneously improve desired product quality through optimal parameter setting using WASPAS and MOORA. Design/methodology/approach Metal matrix composites were fabricated using stir casting process, with aluminum 6063 as matrix and titanium carbide as reinforcement. Fabricated composite samples were machined on medium duty lathe using cemented carbide tool. All the experiments were carried out based on Box–Behnken design. Comparison of multi objective optimization based on ratio analysis and weighted aggregated sum product assessment in optimizing four parameters, namely, “cutting speed,” “feed rate,” “depth of cut” and “reinforcement weight percent of composite samples”; evaluating their influence on material removal rate, cutting force and surface roughness were carried out. Findings The output achieved by both MOORA and WASPAS are in similar MCDM) techniques in the selection of machining parameters. Practical implications The results obtained in the present paper will be helpful for decision makers in manufacturing industries, who work in metal cutting area, to select the suitable levels for the parameters by implementing the MCDM techniques. Originality/value The novelty of this paper is making an attempt to select better MCDM technique based on the comparison of results obtained for the individual technique.

Possible examinations of stone machining focused on the relationship between technological parameters and surface quality

2013 ◽  
Vol 4 (1) ◽  
pp. 63-68 ◽  
Author(s):  
Zs. Kun ◽  
I. G. Gyurika
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Theoretical Background ◽  
Motion Path ◽  
Depth Of Cut ◽  
Manufacturing Cost ◽  
Technological Parameters ◽  
The Relationship ◽  
Manufacturing Time

Abstract The stone products with different sizes, geometries and materials — like machine tool's bench, measuring machine's board or sculptures, floor tiles — can be produced automatically while the manufacturing engineer uses objective function similar to metal cutting. This function can minimise the manufacturing time or the manufacturing cost, in other cases it can maximise of the tool's life. To use several functions, manufacturing engineers need an overall theoretical background knowledge, which can give useful information about the choosing of technological parameters (e.g. feed rate, depth of cut, or cutting speed), the choosing of applicable tools or especially the choosing of the optimum motion path. A similarly important customer's requirement is the appropriate surface roughness of the machined (cut, sawn or milled) stone product. This paper's first part is about a five-month-long literature review, which summarizes in short the studies (researches and results) considered the most important by the authors. These works are about the investigation of the surface roughness of stone products in stone machining. In the second part of this paper the authors try to determine research possibilities and trends, which can help to specify the relation between the surface roughness and technological parameters. Most of the suggestions of this paper are about stone milling, which is the least investigated machining method in the world.

scholarly journals An Investigation of the High-Frequency Ultrasonic Vibration-Assisted Cutting of Steel Optical Moulds

Micromachines ◽  
2021 ◽  
Vol 12 (4) ◽  
pp. 460
Author(s):  
Canbin Zhang ◽  
Chifai Cheung ◽  
Benjamin Bulla ◽  
Chenyang Zhao
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
High Frequency ◽  
Optical Glass ◽  
Contact Point ◽  
Cutting Speed ◽  
Optical Quality ◽  
Machining Parameters ◽  
Nose Radius ◽  
Cutting Geometry

Ultrasonic vibration-assisted cutting (UVAC) has been regarded as a promising technology to machine difficult-to-machine materials such as tungsten carbide, optical glass, and hardened steel in order to achieve superfinished surfaces. To increase vibration stability to achieve optical surface quality of a workpiece, a high-frequency ultrasonic vibration-assisted cutting system with a vibration frequency of about 104 kHz is used to machine spherical optical steel moulds. A series of experiments are conducted to investigate the effect of machining parameters on the surface roughness of the workpiece including nominal cutting speed, feed rate, tool nose radius, vibration amplitude, and cutting geometry. This research takes into account the effects of the constantly changing contact point on the tool edge with the workpiece induced by the cutting geometry when machining a spherical steel mould. The surface morphology and surface roughness at different regions on the machined mould, with slope degrees (SDs) of 0°, 5°, 10°, and 15°, were measured and analysed. The experimental results show that the arithmetic roughness Sa of the workpiece increases gradually with increasing slope degree. By using optimised cutting parameters, a constant surface roughness Sa of 3 nm to 4 nm at different slope degrees was achieved by the applied high-frequency UVAC technique. This study provides guidance for ultra-precision machining of steel moulds with great variation in slope degree in the pursuit of optical quality on the whole surface.

Analysis of tool vibration and surface roughness during turning process of tempered steel samples using Taguchi method

2021 ◽  
pp. 095440892110019
Author(s):  
Menderes Kam ◽  
Mustafa Demirtaş
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Turning Process ◽  
Machining Time ◽  
Tool Vibration ◽  
Control Factors ◽  
Tempered Steel

This study analyzed the tool vibration (Vib) and surface roughness (Ra) during turning of AISI 4340 (34CrNiMo6) tempered steel samples using Taguchi Method. In this context, Taguchi design L18 (21 × 32) was used to analyze the experimental results. The vibration amplitude values from cutting tools were recorded for different machining parameters, control factors; two different sample hardness (46 and 53 HRc), three different cutting speeds (180, 220, 260 m.min−1), and feed rates (0.08, 0.14, 0.20 mm.rev−1) were selected. The machining parameters giving optimum Vib and Ra values were determined. Regression analysis is applied to predict values of Vib and Ra. Analysis of variance was used to determine the effects of machining parameters on the Vib and Ra values. The most important machining parameters were found to be the feed rate, sample hardness, and cutting speed for Vib and Ra, respectively. The lowest Vib and Ra values were obtained in 46 HRc sample as 0.0022 gRMS and 0.255 µm, respectively. The surface quality can be improved by reducing the sources of vibration by using appropriate machining parameters. As a result, there is a significant relationship between Ra and Vib. The lower Ra values were found during turning process of tempered steel samples according to the literature studies. It is suggested that the process can be preferred as an alternative process to grinding process due to lower cost and machining time. In application of the turning of experiment samples by ceramic cutting tool, a substantial technological and economical benefit has been observed.

scholarly journals Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

1970 ◽  
Vol 2 (1) ◽  
Author(s):  
A.K.M.N. Amin, M.A. Rizal, and M. Razman
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Metal Removal ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
End Mill ◽  
Machined Surface ◽  
Operating Cycle ◽  
Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Effects of Machining Parameters on Surface Roughness when Ultra-High Precision Diamond Turning RSA443 Optical Aluminum

2019 ◽  
Vol 287 ◽  
pp. 30-34
Author(s):  
Zwelinzima Mkoko ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Silicon Content ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Turning Process ◽  
Optical Components ◽  
Box Behnken Design ◽  
Factors Influencing

In the globally competitive environment, surface roughness and finer tolerances are becoming stringent and certainly most critical for optical components. The aim of this study is to determine the effects of diamond turning process parameters on surface finish when diamond turning RSA 443 alloy having high silicon content. This alloy is a new grade of aluminum that has a potential to be used for production of various optical components. The experiments were conducted based on the Box-Behnken design with three diamond-turning parameters varied at three levels. A mathematical regression model was developed for predicting surface roughness. Further, the analysis of variance was used to analyze the influence of cutting parameters and their interaction in machining. The developed prediction model reveals that cutting speed and feed rate are the most dominant diamond turning factors influencing surface roughness.

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