An Experimental Investigation of the Laser Milling Process for Polycrystalline Diamonds

2011 ◽  
Vol 291-294 ◽  
pp. 810-815 ◽  
Author(s):  
Qi Wu ◽  
Jun Wang
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Polycrystalline Diamond ◽  
Milling Process ◽  
Depth Of Cut ◽  
Good Surface ◽  
Laser Milling ◽  
Cavity Profile ◽  
Profile Depth ◽  
Good Surface Finish

An experimental study of the pulsed laser milling process for a sintered polycrystalline diamond is presented. The characteristics and quality of the cavities machined with a Yd laser under different pulse energies, pulse overlaps, scan overlaps and numbers of passes are discussed, together with the effects of these parameters on the cavity profile, depth of cut and surface roughness. A statistical analysis is also presented to study the relationship between the process parameters and surface roughness. It shows that the optimum pulse overlap and pulse energy may be used to achieve good surface finish, whereas scan overlap and number of passes can be selected to improve the depth of cut without much effect on the surface finish.

scholarly journals Tribological Behavior and Analysis on Surface Roughness of CNC Milled Dual Heat Treated Al6061 Composites

2021 ◽  
Vol 2021 ◽  
pp. 1-14
Author(s):  
A. Bovas Herbert Bejaxhin ◽  
G.M. Balamurugan ◽  
S.M. Sivagami ◽  
K. Ramkumar ◽  
V. Vijayan ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Surface Roughness ◽  
Lower Surface ◽  
Cnc Machining ◽  
Depth Of Cut ◽  
Good Surface ◽  
Heat Treated ◽  
Good Surface Finish ◽  
Artificial Neural Network Ann ◽  
Machining Properties

Dual heat treatment (DHT) effect is analyzed using the machining of Al6061-T6 alloy, a readily available material for quickly finding the machining properties. The heat treatments are conducted twice over the specimen by the furnace heating before processing through CNC machining. The HSS and WC milling cutters are preferred for the diameter of 10 mm for the reviewed rotational speeds of 2000 rpm and 4000 rpm, and the constant depth of cut of 0.5 mm is chosen based on various reviews. Worthy roughness could be provided mostly by the influence of feed rates preferred here as 0.05 mm/rev and 0.1 mm/rev. The influencing factors are identified by the Taguchi, genetic algorithm (GA), and Artificial Neural Network (ANN) techniques and compared within it. The simulation finding also helps to clarify the relationship between influenced machining constraints and roughness outcomes of this project. The average values of heat treated and nonheat treated Al6061-T6 are compared and it is to be evaluated that 41% improvement is obtained with the lower surface roughness of 1.78975 µm and it shows good surface finish with the help of dual heat treatment process.

Experimental Investigation of Electrochemical Micro Turning of Ti6Al4V With NaOH Solution

2020 ◽  
Author(s):  
Arnab Das ◽  
Deepak Kumar ◽  
Mohan Kumar ◽  
Vivek Bajpai
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Material Removal ◽  
Electrochemical Machining ◽  
Electrode Gap ◽  
Machining Time ◽  
Good Surface ◽  
Naoh Solution ◽  
Micro Turning ◽  
Good Surface Finish

Abstract Ti6Al4V is a highly favorable material in biomedical, aerospace and many other industries. However, rapid tool wear during machining has made Ti6Al4V into a difficult-to-machine material. Electrochemical machining may be a solution to that challenge. Moreover, high chemical affinity and formation of oxide layer over the surface have limited the application electrochemical machining for Ti6Al4V. In this paper, an experimental approach of electrochemical micro turning of Ti6Al4V has been described. The electrolyte was 10% aqueous solution of NaOH and the tool was SS 310. For each and every experiment workpiece rotational speed and machining time were kept constant. Constant DC voltage was applied and the inter-electrode gap between tool and workpiece was kept constant for each experiment. Experiments were performed using two different levels of applied voltage, axial feed rate and inter-electrode gap. Their effects over MRR and surface roughness have been determined. Additionally, the optimum working condition was determined in order to maximize MRR and minimize surface roughness. For each experiment, acceptable material removal and good surface finish have been achieved. The maximum surface roughness (Ra) was found 1.128 μm in experiment 1. The utilization of NaOH solution has resulted in controlled electrolyzing current, controlled material removal and therefore, good surface finish.

Investigation on Precision Finishing of Helical Gears Using Newly Developed Silicon Carbide Mixed Styrene Butadiene Media and Abrasive Flow Finishing Process

2021 ◽  
Vol 06 ◽  
Author(s):  
Irfan Ahmad Ansari ◽  
Dipti Sharma ◽  
Kamal K. Kar ◽  
Janakarajan Ramkumar
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Surface Finish ◽  
Helix Angle ◽  
Helical Gears ◽  
Good Surface ◽  
Finishing Process ◽  
Good Surface Finish ◽  
Styrene Butadiene ◽  
Abrasive Flow Finishing

The good surface finish of gears is one of the critical parameters which leads to its noise-free operation, efficient power transmission, and longer service life. However, most of the gear manufacturing processes do not produce a good surface finish. Therefore, gears need post-processing to finish their surface. Out of several methods of gear finishing like gear grinding, lapping, and honing, the abrasive flow finishing process offers more flexibility due to its self-deformable abrasive medium which can easily flow across complex internal or external geometry. The present study aims to improve the surface finish of helical gear by abrasive flow finishing (AFF) by experimentally identifying the optimum range of the potential input process parameters. An AFF set up was used for gear finishing by using a medium of styrene-butadiene and soft silicone polymer, Silicon carbide abrasive, and silicone oil as a blending agent. A special fixture was developed comprising of five parts namely spider, mandrel, upper, middle, and bottom cylinder with a circumferential hole, which allows the back and forth movement of AFF medium through the annular volume between fixture and gear. Further, an experimental investigation of process parameters like viscosity, effect of percentage of various components in medium, operating pressure, and helix angle of helical gears have been studied on percentage improvement of surface roughness (Ra) value of the gear. It is found that the concentration of abrasives in media and extrusion pressure were the two most significant parameters that have a maximum effect on the percentage reduction in surface roughness and finishing rate. Results show that the optimum combination of the extrusion pressure and abrasive weight percentage is 38 bar and 40 % that produces best results of around 76 and 69 % improvement in Ra for gear of helix angle 30 degree and 45 degree respectively.

scholarly journals Optimization of Machining Parameters for MRR and Surface Roughness for 7024 AL-alloy in Pocket Milling Process

2019 ◽  
Vol 26 (1) ◽  
pp. 10-16
Author(s):  
Mustafa Mohammed Abdulrazaq ◽  
Adil Shabeeb Jaber ◽  
Ahmed Salman Hammood ◽  
Ahmed Ghazi Abdulameer
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Milling Process ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Machining Parameters ◽  
Good Surface ◽  
Good Surface Roughness

The objective of this work is the investigation of milling process variables which resulting in optimal values of the surface roughness and material removal rate during machining of 7024 Al-alloy. The machining operation implemented on C-TEK CNC milling machine. The effects of the selected parameters on the chosen characteristics have been accomplished using Taguchi’s parameter design approach; also ANOVA had been used to evaluate the contribution of each parameter on the process outputs. Different feed rates are used ranging from (60, 80 and 100) mm/min, found that high feed rates gives a high material removal rates and good surface roughness. On the other hand, using three levels of spindle speeds found that a higher spindle speeds gives better surface roughness with a little effect on MRR. The process results showed that maximum MRR achieved (2.40) mm3/min when machining feed rate (100) mm/min, spindle speed (1000) r.p.m, and depth of cut (0.6) mm while good surface roughness (0.41 µm) when machining feed rate (100) mm/min, spindle speed (1000) r.p.m, and depth of cut (0.2) mm. The level of importance of the machining parameters for material removal rate and surface roughness and is determined by using Taguchi designing experiments and the variance analysis (ANOVA).

The effect of abrasive hardness on the chemical-assisted polishing of (0001) plane sapphire

2005 ◽  
Vol 20 (2) ◽  
pp. 504-520 ◽  
Author(s):  
Honglin Zhu ◽  
Dale E. Niesz ◽  
Victor A. Greenhut ◽  
Robert Sabia
Keyword(s):  
Surface Finish ◽  
Reaction Layer ◽  
Basal Plane ◽  
Material Removal ◽  
Plane Surface ◽  
Abrasive Particle ◽  
Polycrystalline Diamond ◽  
Hydration Layer ◽  
Good Surface ◽  
Good Surface Finish

A series of abrasives with various hardness values including monocrystalline and polycrystalline diamond, α- and γ-alumina, zirconia, ceria, and silica were used to examine the concept of chemical-assisted polishing for finishing the (0001), c-plane (basal plane), of sapphire. Diaspore, a monohydrate of alumina, was also evaluated. Atomic force microscopy suggested that the hydrated layer of the c-plane surface was about 1 nm thick. Polishing experiments were designed to determine whether the chemically modified surface hydration layer forms on the basal plane in water. The results indicate that harder abrasives do not necessarily cause faster material removal and better surface finish for similar abrasive particle size. Abrasives with hardness equal to or less than sapphire such as α-Al2O3 and γ-Al2O3 achieved the best surface finish and greatest efficiency of material removal. It is proposed that the (0001) c-plane sapphire surface was modified by water to form a thin hydration layer with structure and hardness close to diaspore. This reaction layer can be removed by an abrasive that is softer than sapphire but harder than the reaction layer. α-Al2O3 was particularly effective. This result is attributed to adhesion between identical reaction layers on the basal planes of the alumina abrasive and the sapphire. This demonstrates that high removal rates and good surface finish can be achieved without costly diamond polishing.

Surface Integrity and Cutting Temperature in Machining of Biomedical Magnesium Alloys an Overview

2013 ◽  
Vol 748 ◽  
pp. 7-10 ◽  
Author(s):  
Turnad Lenggo Gintar ◽  
Fawad Hasan ◽  
Ahmad Majdi Abdul Rani ◽  
Ariwahjoedi Bambang
Keyword(s):  
Magnesium Alloys ◽  
Surface Integrity ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Good Surface ◽  
Good Surface Finish ◽  
Quality Surface

This review provides some recent progress of the research in machinability assessment of magnesium alloys. Surface integrity and cutting temperature as the main machinability terms are widely discussed in this paper. Machining parameters, such as cutting speed, feed, depth of cut, play important roles in developing good surface finish and high quality surface integrity. Achieving good surface finish (low surface roughness) is a main objective in machining, especially for biomedical applications. Cutting temperature during machining has to be taken into considerations. High temperature during cutting leads to low surface finish and higher tool wear rate, leading to low tool life and poorer surface finish.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Manufacturability of Aircraft Winglet for Wind Tunnel Testing

2015 ◽  
Vol 830-831 ◽  
pp. 100-103
Author(s):  
L. Gopinath ◽  
S. Ravishankar
Keyword(s):  
Wind Tunnel ◽  
Metal Cutting ◽  
Tool Path ◽  
Cutting Parameters ◽  
Cnc Machining ◽  
Depth Of Cut ◽  
Manufacturing Strategy ◽  
Thin Sections ◽  
Good Surface ◽  
Good Surface Finish

The form, shape and dimensions of the scaled down winglet model become small and thin bringing complexity to manufacturing. The trailing edge tapers to a thickness varying from 0.065mm to 0.099mm along its length. The mounting portion of the winglet is provided with a close tolerance having a slot gap of 5mm and a depth of 35 mm with an angle. Additionally, wind tunnel models require good surface finish on the aerodynamic surfaces and this involves adopting a manufacturing strategy with a control over on the metal cutting parameters to be implemented on a three axes CNC machining centre. The winglet surface is divided into segments in order to handle the cutting forces on the varying aerodynamic cross section. Various metal cutting parameters such as tool path, cutter diameter, feed rate, depth of cut, spindle speed, etc., are evaluated by monitoring segments where the metal cutting is carried out [1] and flow of chips observed. Fixtures and lugs are planned effectively to accommodate the machining of the angular slot in a three axes machining centre itself. Routing of operations to handle the varying thin sections and realisation of the close tolerance slot has enabled a reliable manufacturing approach in an economical way.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

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