The Optimization in Machining AISI 1030 Using Taguchi Method for Dry and Flood Cutting Condition

2013 ◽  
Vol 315 ◽  
pp. 841-845
Author(s):  
Noor Hakim Rafai ◽  
Mohd Hilmi Othman ◽  
Sulaiman Hasan ◽  
Tharmaah Rao A/L Sinnasalam
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Feed Rate ◽  
Cutting Speed ◽  
Lower Surface ◽  
Quality Characteristic ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Cnc Milling ◽  
Dry Cutting

This research is an approach to investigate the effect of cutting condition on surface roughness in dry and flood cutting of AISI 1030. The objectives of this project are to compare the plastic injection mould quality between dry and flood cutting condition, as well as to determine the best cutting condition. The parameters used were depth of cut (0.25mm, 0.5mm, and 1.0mm), feed rate (50mm/rev, 100mm/rev and 150mm/rev) and cutting speed (700m/min, 1400m/min and 2100m/min). Surface roughness value was used to determine to quality characteristic of the machined mould. The experiments were done using Mazak CNC milling machine and the material selected was AISI 1030, which is a medium tensile and low hardenability carbon steel. Twenty-seven runs were done in both dry and flood cutting, adapting Taguchi Method - Orthogonal Array. After each machining, the surface roughness was measured using Mitutoyo Surface Roughness Tester. The data obtained was then analyzed through Signal to Noise Ratio calculation. This analysis produced the best combination of parameters which gives the lowest surface roughness. The best combinations for dry cutting are 2100m/min for cutting speed, 50mm/rev for feed rate and 0.25mmfor depth of cut. As for flood cutting, the best combinations are 2100m/min for cutting speed, 50mm/rev for feed rate and 1.0mm for depth of cut. The surface roughness obtained using this parameter in dry cutting is 0.27Ám and 0.40Ám in flood cutting. From the comparison, it is proved that dry cutting produced lower surface roughness compared to flood cutting.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

Effects of Cutting Condition on Surface Roughness when Turning Untreated and Sb-Treated Al-11%Si Alloys Using PVD Coated Tools

2013 ◽  
Vol 315 ◽  
pp. 413-417 ◽  
Author(s):  
Mohsen Marani Barzani ◽  
Mohd Yusof Noordin ◽  
Ali Akhavan Farid ◽  
Saaed Farahany ◽  
Ali Davoudinejad
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Manufacturing Processes ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Fabrication Cost ◽  
Coated Tools ◽  
Experimental Trials ◽  
Cutting Speeds

Surface roughness is an important output in different manufacturing processes. Its characteristic affects directly the performance of mechanical components and the fabrication cost. In this current work, an experimental investigation was conducted to determine the effects of various cutting speeds and feed rates on surface roughness in turning the untreated and Sb-treated Al-11%Si alloys. Experimental trials carried out using PVD TIN coated inserts. Experiments accomplished under oblique dry cutting when three different cutting speeds have been used at 70, 130 and 250 m/min with feed rates of 0.05, 0.1 and 0.15 mm/rev, whereas depth of cut kept constant at 0.05 mm. The results showed that Sb-treated Al-11%Si alloys have poor surface roughness in comparison to untreated Al-11%Si alloy. The surface roughness values reduce with cutting speed increment from 70 m/min to 250 m/min. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev.

Investigation of Chip and Surface Roughness when Milling AISI304 Stainless Steel

2017 ◽  
Vol 889 ◽  
pp. 152-158
Author(s):  
K. Kadirgama ◽  
K. Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Feed Rate ◽  
Prediction Models ◽  
Cutting Speed ◽  
Experimental Result ◽  
Quadratic Model ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Axial Depth

Stainless steel was used for many engineering applications. The optimum parameters needs to be identify to save the cutting tool usage and increase productivity. The purpose of this study is to develop the surface roughness mathematical model for AISI 304 stainless steel when milling using TiN (CVD) carbide tool. The milling process was done under various cutting condition which is cutting speed (1500, 2000 and 2500 rpm), feed rate (0.02, 0.03 and 0.04 mm/tooth) and axial depth (0.1, 0.2 and 0.3 mm). The first order model and quadratic model have been developed using Response Surface Method (RSM) with confident level 95%. The prediction models were comparing with the actual experimental results. It is found that quadratic model much fit the experimental result compare to linear model. In general, the results obtained from the mathematical models were in good agreement with those obtained from the machining experiments. Besides that, it is shown that the influence of cutting speed and feed rate are much higher on surface roughness compare to depth of cut. The optimum cutting speed, feed rate and axial depth is 2500 rpm, 0.0212 mm/tooth and 0.3mm respectively. Besides that, continues chip is produced at cutting speed 2500 rpm meanwhile discontinues chip produced at cutting speed 1500 rpm.

scholarly journals Analysis and Optimization of Cutting Tool Coating Effects on Surface Roughness and Cutting Forces on Turning of AA 6061 Alloy

2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
Mahir Akgün ◽  
Fuat Kara
Keyword(s):  
Surface Roughness ◽  
Mathematical Models ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Machined Surface ◽  
Tool Coating ◽  
Cutting Inserts

The present work has been focused on cutting force (Fc) and analysis of machined surface in turning of AA 6061 alloy with uncoated and PVD-TiB2 coated cutting inserts. Turning tests have been conducted on a CNC turning under dry cutting conditions based on Taguchi L18 (21 × 33) array. Kistler 9257A type dynamometer and equipment have been used in measuring the main cutting force (Fc) in turning experiments. Analysis of variance (ANOVA) has been applied to define the effect levels of the turning parameters on Fc and Ra. Moreover, the mathematical models for Fc and Ra have been developed via linear and quadratic regression models. The results indicated that the best performance in terms of Fc and Ra was obtained at an uncoated insert, cutting speed of 350 m/min, feed rate of 0.1 mm/rev, and depth of cut of 1 mm. Moreover, the feed rate is the most influential parameter on Ra and Fc, with 64.28% and 54.9%, respectively. The developed mathematical models for cutting force (Fc) and surface roughness (Ra) present reliable results with coefficients of determination (R2) of 96.04% and 92.15%, respectively.

Investigations on the Effect of CNC Dry Hard Turning Process Parameters on Surface Integrity: A Multi-performance Characteristics Optimization

2014 ◽  
Vol 14 (1) ◽  
pp. 23-30 ◽  
Author(s):  
Suha K. Shihab ◽  
Zahid A. Khan ◽  
Aas Mohammad ◽  
Arshad Noor Siddiquee
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Influential Factor ◽  
Depth Of Cut ◽  
Micro Hardness ◽  
Dry Cutting

AbstractThe cutting parameters such as the cutting speed, the feed rate, the depth of cut, etc. are expected to affect the two constituents of surface integrity (SI), i.e., surface roughness and micro-hardness. An attempt has been made in this paper to investigate the effect of the CNC hard turning parameters on the surface roughness average (Ra) and the micro-hardness (μh) of AISI 52100 hard steel under dry cutting conditions. Nine experimental runs based on an orthogonal array of the Taguchi method were performed and grey relational analysis method was subsequently applied to determine an optimal cutting parameter setting. The feed rate was found to be the most influential factor for both the Ra and the μh. Further, the results of the analysis of variance (ANOVA) revealed that the cutting speed is the most significant controlled factor for affecting the SI in the turning operation according to the weighted sum grade of the surface roughness average and micro-hardness.

The Influence of Cutting Parameters of Turning Process on the Oil Palm Wood Using Carbide Tool

2013 ◽  
Vol 415 ◽  
pp. 666-671
Author(s):  
Surasit Rawangwong ◽  
Jaknarin Chatthong ◽  
Worapong Boonchouytan
Keyword(s):  
Surface Roughness ◽  
Oil Palm ◽  
Feed Rate ◽  
Cutting Speed ◽  
Experimental Result ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Turning Process ◽  
Main Factors

This research study aimed to investigate the effect of main factors on the surface roughness in oil palm wood turning process for manufacturing furniture parts using carbide tools. The main factors, namely, cutting speed, feed rate and depth of cut were investigated for the optimum surface roughness in furniture manufacturing process. The result of preliminary trial shown that the depth of cut had no effect on surface roughness. Moreover, the experiment was found that the factors affecting a surface roughness were cutting speed and feed rate, with having tendency for reduction of roughness value at lower feed rate and greater cutting speed, Therefore in the turning process of oil palm wood, it was possible to determine a cutting condition by means of the equation Ra = 19.8-0.00742 Cutting Speed+3.98 Feed rate, This equation can be best used with limitation of cutting speed at 122-450 m/min, feed rate at 0.1-0.5 mm/rev and depth of cut does not over 1 mm,. To confirm the experiment result, a comparison between the equation value and an actual value by estimating a prediction error value was calculate with the surface roughness and margin of error does not over 10%. The experimental result reveals the mean absolute percentage error (MAPE) of the equation of surface roughness is 3.24%, which is less than the predicted error value and it is acceptable.

scholarly journals Optimization of Cutting Parameters on Turning Process Based on Surface Roughness Using Response Surface Methodology

2011 ◽  
Vol 117-119 ◽  
pp. 1561-1565
Author(s):  
Muhammad Yusuf ◽  
Mohd Khairol Anuar Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Optimization Of Cutting Parameters

This paper describes effect of cutting parameters on surface roughness for turning of aluminium alloy 7050 using carbide cutting tool with dry cutting condition. The model is developed based on cutting speed, feed rate and depth of cut as the parameters of cutting process. The selection of cutting process was based on the design of experiments Response Surface Methodology (RSM). The objective of this research is finding the optimum cutting parameters based on surface roughness. The relation between cutting parameters and surface roughness were discussed.

Modeling the Surface Roughness for Fine Turning of AISI304 Stainless Steel

2007 ◽  
Vol 364-366 ◽  
pp. 644-648 ◽  
Author(s):  
Wei Shin Lin
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Prediction Model ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Variable Surface ◽  
Fine Turning

High ductility, high strength, high work hardening rate and low thermal conductivity of stainless steels are the main factors that make their machinability difficult. In this study, determination of the optimum cutting condition has been aimed at when fine turning an AISI 304 austenitic stainless steel using ceramic cutting tools. The cutting speeds for the turning test were from 80 to 320 m / min, feed rates were from 0.04 to 0.10 mm / rev and the depth of cut was fixed at 0.1 mm. According to the test results, we can find that the values of surface roughness were decreased when the cutting speed was increasing, and decrease with the decrease of feed rate. But when the cutting speed was greater than 360 m / min, or the feed rate was smaller than 0.02 mm / rev，the surface roughness would be deteriorated because of the chatter phenomenon. In this paper, a polynomial network is adopted to construct a prediction model on surface roughness for fine turning of AISI304 austenitic stainless steel. The polynomial network is composed of a number of functional nodes. These functional nodes are self-organized to form an optimal network architecture by using a predicted square error (PSE) criterion. It is shown that the polynomial network can correctly correlate the input variables (cutting speed and feed rate) with the output variable (surface roughness). Based on the surface roughness prediction model constructed, the surface roughness of the workpiece can be predicted with reasonable accuracy if the turning conditions are given and it is also consistent with the experimental results very well.

scholarly journals Surface Quality and Chip Formation in Turning of LM6 Aluminium Alloy and Particulate Reinforced Metal Matrix Composite

2013 ◽  
Vol 773-774 ◽  
pp. 894-901
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Surface Quality ◽  
Chip Formation ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Cutting Condition

Majority of the components of aerospace and automotive vehicles need different machining operations, mainly for the assembly requirements. The components have to present both high dimensional precision and surface quality. This present work is concerned with the effect of cutting parameters (cutting speed, feed rate and depth of cut) on the surface roughness and the chip formation in turning process. The machining results are compared with LM6 aluminium alloy and TiC reinforced metal matrix composite under the same cutting conditions and tool geometry. The cutting condition models designed based on the Design of Experiments Response Surface Methodology. The objective of this research is to obtaining the optimum cutting parameters to get a better surface quality and also the chip formation and furthermore does not hazardous to the worker and the machined products quality. Results shows that Surface roughness values of LM6-TiC composite are higher as compared LM6 alloy at similar cutting condition. With increasing in cutting speed improves the surface quality. The surface quality increases with decrease of the feed rate and the depth of cut. There are difference chip forms for LM6 aluminium alloy and Al-TiC composite for a similar of cutting condition. Generally, chip formations of both materials are acceptable and favourable for the worker as well as the products and the tools.

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