A Data Dependent Systems Approach to Dynamics of Surface Generation in Turning

1981 ◽  
Vol 103 (4) ◽  
pp. 437-445 ◽  
Author(s):  
S. M. Pandit ◽  
S. Revach
Keyword(s):  
Surface Roughness ◽  
Fourier Transform ◽  
Metal Cutting ◽  
Systems Approach ◽  
Cutting Conditions ◽  
Surface Generation ◽  
Chip Surface ◽  
Workpiece Surface ◽  
Independent Estimate ◽  
Micro Morphology

A new investigative approach to metal cutting dynamics is proposed based on wavelength decomposition of surface roughness by data dependent systems (DDS). This approach distinguishes from the commonly used Fourier transform analysis. It is shown to be capable of throwing light on both macroscopic and microscopic aspects of cutting mechanics. Workpiece surfaces from turning experiments, changing only speed and only feed, are used to illustrate that the macro-effects of cutting conditions and vibrations can be related to RMS components due to large wavelengths of a few tenths of mm magnitude. In particular, the so-called Spanzipfel effect is accounted for and its RMS is derived. It is also shown that wavelengths of a few micrometer magnitude, estimated from the workpiece surface roughness, seem to provide an independent estimate of chip surface lamellar widths in micro-morphology, well in agreement with earlier investigations.

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.

The Influence of Cutting Conditions on Surface Roughness during Steel 100Cr6 Grinding

2017 ◽  
Vol 261 ◽  
pp. 215-220
Author(s):  
Martin Novák ◽  
Natasa Naprstkova
Keyword(s):  
Surface Roughness ◽  
Bearing Steel ◽  
Cutting Conditions ◽  
Machining Process ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Bearing Steels ◽  
Technology Products ◽  
Machined Surface Roughness

Machining of tool steels is often an important used technology. Products made from these materials are often used in mechanical engineering, and quality of workpiece surface roughness after machining respective grinding is one of the important parameters that to us speak about the quality of the machining process. The paper deals with the influence of cutting conditions when grinding bearing steel 100Cr (EN ISO) on machined surface roughness. This steel belongs to a group of bearing steels.

The Influence of Cutting Conditions on Surface Roughness during Steel X38CrMoV5 Grinding

2013 ◽  
Vol 581 ◽  
pp. 247-254 ◽  
Author(s):  
Martin Novák ◽  
Natasa Naprstkova
Keyword(s):  
Surface Roughness ◽  
Cutting Conditions ◽  
Machining Process ◽  
Tool Steels ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Technology Products ◽  
Machined Surface Roughness ◽  
Grinding Tool

Machining of tool steels is often an important used technology. Products made from these materials are often used in mechanical engineering, and quality of workpiece surface roughness after machining respective grinding is one of the important parameters that to us speak about the quality of the machining process. The paper deals with the influence of cutting conditions when grinding tool steel X38CrMoV5 (EN ISO) on machined surface roughness.

scholarly journals FEM-Based Study of Precision Hard Turning of Stainless Steel 316L

Materials ◽  
2019 ◽  
Vol 12 (16) ◽  
pp. 2522 ◽  
Author(s):  
Ahmed Elkaseer ◽  
Ali Abdelaziz ◽  
Mohammed Saber ◽  
Ahmed Nassef
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Process Parameters ◽  
Chip Formation ◽  
Feed Rate ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Surface Generation ◽  
Stainless Steel 316L ◽  
Edge Radius

This study aims to investigate chip formation and surface generation during the precision turning of stainless steel 316L samples. A Finite Element Method (FEM) was used to simulate the chipping process of the stainless steel but with only a restricted number of process parameters. A set of turning tests was carried out using tungsten carbide tools under similar cutting conditions to validate the results obtained from the FEM for the chipping process and at the same time to experimentally examine the generated surface roughness. These results helped in the analysis and understanding the chip formation process and the surface generation phenomena during the cutting process, especially on micro scale. Good agreement between experiments and FEM results was found, which confirmed that the cutting process was accurately simulated by the FEM and allowed the identification of the optimum process parameters to ensure high performance. Results obtained from the simulation revealed that, an applied feed equals to 0.75 of edge radius of new cutting tool is the optimal cutting conditions for stainless steel 316L. Moreover, the experimental results demonstrated that in contrast to conventional turning processes, a nonlinear relationship was found between the feed rate and obtainable surface roughness, with a minimum surface roughness obtained when the feed rate laid between 0.75 and 1.25 times the original cutting edge radius, for new and worn tools, respectively.

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. 

Budding Assembly Accuracy in the Presence of Workpiece Surface Roughness and Dimensional Error

2002 ◽  
Author(s):  
Grace H. Yu ◽  
Dariusz Ceglarek ◽  
Neville K. S. Lee
Keyword(s):  
Surface Roughness ◽  
Surface Generation ◽  
Simulation Methods ◽  
Surface Waviness ◽  
Dimensional Error ◽  
Workpiece Surface ◽  
Assembly Accuracy ◽  
Dimensional Errors

In this paper, simulation methods with improved surface generation techniques are used to study the accuracy of budding assembly processes. Our analysis shows that both the dimensional error and surface roughness together with surface waviness have significant effect on the budding assembly accuracy. In addition, we have found that even for the same parts with given dimensional errors, surface roughness and waviness, the budding assembly accuracy can still vary significantly depending on the different approaches of the alignment processes.

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.

Abrasive Waterjet Cutting of Aluminum Alloys: Workpiece Surface Roughness

2013 ◽  
Vol 404 ◽  
pp. 3-9 ◽  
Author(s):  
Nihat Tosun ◽  
Ihsan Dagtekin ◽  
Latif Ozler ◽  
Ahmet Deniz
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Aluminum Alloys ◽  
Abrasive Waterjet ◽  
Traditional Methods ◽  
Workpiece Surface ◽  
Abrasive Waterjet Machining ◽  
Waterjet Machining ◽  
Area Of Application ◽  
Better Than

Abrasive waterjet machining is one of the non-traditional methods of the recent years which found itself a wide area of application in the industry for machining of different materials. In this paper, the surface roughness of 6061-T6 and 7075-T6 aluminum alloys are being cut with abrasive waterjet is examined experimentally. The experiments were conducted with different waterjet pressures and traverse speeds. It has been found that the surface roughness obtained by cutting material with high mechanical properties is better than that of obtained by cutting material with inferior mechanical properties.

Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

2016 ◽  
Author(s):  
Issam Abu-Mahfouz ◽  
Amit Banerjee ◽  
A. H. M. Esfakur Rahman
Keyword(s):  
Surface Roughness ◽  
Fuzzy Clustering ◽  
Wavelet Transforms ◽  
Fourier Transforms ◽  
End Milling ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machined Surface ◽  
Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

Effect of Cutting Parameters on Surface Roughness in Turning of Bone

2013 ◽  
Vol 845 ◽  
pp. 708-712 ◽  
Author(s):  
P.Y.M. Wibowo Ndaruhadi ◽  
S. Sharif ◽  
M.Y. Noordin ◽  
Denni Kurniawan
Keyword(s):  
Surface Roughness ◽  
Bone Tissue ◽  
Influencing Factor ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Machining Process ◽  
Turning Operation ◽  
Cutting Direction

Surface roughness indicates the damage of the bone tissue due to bone machining process. Aiming at inducing the least damage, this study evaluates the effect of some cutting conditions to the surface roughness of machined bone. In the turning operation performed, the variables are cutting speed (26 and 45 m/min), feed (0.05 and 0.09 mm/rev), tool type (coated and uncoated), and cutting direction (longitudinal and transversal). It was found that feed did not significantly influence surface roughness. Among the influencing factor, the rank is tool type, cutting speed, and cutting direction.

Sign in / Sign up

Export Citation Format

Share Document