Investigation of Heat Assisted High Speed End Milling of Soda Lime Glass for Surface Generation

2017 ◽  
Vol 740 ◽  
pp. 145-151
Author(s):  
Mohamed Konneh ◽  
Mst. Nasima Bagum ◽  
A.K.M. Nurul Amin ◽  
Amira Fatin Asyah
Keyword(s):  
Surface Finish ◽  
Feed Rate ◽  
High Speed ◽  
End Milling ◽  
Heating Temperature ◽  
Soda Lime ◽  
Surface Generation ◽  
Quadratic Model ◽  
Depth Of Cut ◽  
Soda Lime Glass

Brittle materials like soda lime glass can be machined in ductile mode under controlled machining conditions (feed rate, depth of cut, small tool edge radius) using high speed to generate a desired surface finish. The heat generated in high speed machining tends to promote ductile machining. In this paper, heat assisted high speed end milling is investigated to explore machinability of the soda lime glass. The heat assisted machining thus generates low surface finish on the machined workpiece. The heat assisted high speed end milling of soda lime was carried out using uncoated 2 flute carbide end mill at a constant depth of cut 25 μm, while the spindle speed and feed rate were varied from 30,000 to 50,000 rpm and 45 to 75 mm/min, respectively. The applied temperature was varied from 200 °C to 300 °C. The observations of machined surface were done on Surf-test (SV-514) and Scanning Electron microscope (SEM). A quadratic model for roughness (Ra) was developed using Central Composite Design of experiment. The optimum Ra, 0.10 μm was achieved at 49,570 rpm, 58 mm/min feed rate and heating temperature at 238°C. It is found that cutting speed has the greatest influence on the surface roughness value, followed by feed rate and heating temperature.

A New Experimental Approach to Determination of Critical Depth in High Speed Machining of Soda-Lime Glass

2012 ◽  
Vol 576 ◽  
pp. 23-27
Author(s):  
M.A. Mahmud ◽  
A.K.M. Nurul Amin ◽  
M.D. Arif
Keyword(s):  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Critical Depth ◽  
Good Surface ◽  
Transition Depth ◽  
Good Surface Finish

Soda-Lime glass is a very hard and brittle material which is commonly used as window panels and many other common applications. Due to its low fracture toughness it is very difficult to machine and obtain good surface finish under nornal cutting conditions. Hence, machining has to be done in ways to avoid brittle fracture on the finished machined surface. Such machining is only possible under ductile mode machining conditions when the removal of material is performed in the plastic state. However, ductile mode machining requires that during machining the temperature generated in the cutting zone in the working temperature range of glass to avoid crack formation during machining. This makes all types of machining of glass an extremely challenging affair, given the current state and mode of mechanical machining. This research paper elucidates the results of an experimental study for determination of critical depth of cut as a function of cutting parameters in high speed end milling of soda-lime glass. The critical depth is defined as the depth of cut at which crack formation the material is initiated for a given high speed attachment. In determining the critical depth as well as the ductile brittle transition depth, machining was performed on a tapered surface. Vibration signals from an accelerometer in time domain (amplitude vs. time display) and the surface characteristics were used in identifying the critical depth of cut. The new method has been found to be useful in online determination of the critical depth, as well as the brittle-ductile transition depth, for generating crack-free surfaces with good surface finish in high speed end milling of soda lime glass.

Surface Roughness Model for High Speed End Milling of Soda Lime Glass Using Carbide Coated Tools with Compressed Air Blowing

2012 ◽  
Vol 576 ◽  
pp. 107-110
Author(s):  
M.A. Mahmud ◽  
A.K.M. Nurul Amin ◽  
Muammer Din Arif
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Gas Turbines ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Machining Parameters ◽  
Machined Surface

Glass materials play a vital role in advancement of science and technology. They have found wide spread application in the industry, in laboratory equipment and in micro-gas turbines. Due to their low fracture toughness they are very difficult to machine, moreover there are the chip depositions on the machined surface which affects surface finish under ductile mode cutting conditions. In this research, high speed end milling of soda lime glass is performed on CNC vertical milling machine to investigate the effects of machining parameters i.e. spindle speed, depth of cut, and feed rate on machined surface roughness. Design of experiments was performed following Central Composite Design (CCD) of Response Surface Methodology (RSM). Design Expert Software was used for generating the empirical mathematical model for average surface roughness. The model’s validity was tested to 95% confidence level by Analysis of Variance (ANOVA). Subsequent experimental results showed that the developed mathematical model could successfully describe the performance indicators, i.e. surface roughness, within the controlled limits of the factors that were considered.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

An Experimental Approach to Determine the Critical Depth of Cut in Brittle-to-Ductile Phase Transition During End Milling of Soda-Lime Glass

2016 ◽  
Vol 41 (11) ◽  
pp. 4553-4562 ◽  
Author(s):  
A. K. M. Nurul Amin ◽  
Mst. Nasima Bagum ◽  
Noor Fathiah ◽  
Mohamed Konneh ◽  
Tasnim Firdaus Bt. Mohamed Ariff
Keyword(s):  
Phase Transition ◽  
Experimental Approach ◽  
End Milling ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Critical Depth ◽  
Ductile Phase ◽  
Critical Depth Of Cut

scholarly journals Machinability of Soda Lime Glass in High Speed End Milling

2018 ◽  
Vol 290 ◽  
pp. 012036
Author(s):  
Mohamed Konneh ◽  
Mst. Nasima Bagum ◽  
Tasnim Firdaus Bt. Mohamed Arif ◽  
Mohammad Yeakub Ali
Keyword(s):  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Soda Lime Glass

Achievement of Ductile Regime Machining in High Speed End Milling of Soda Lime Glass by Using Tungsten Carbide Tool Insert

2015 ◽  
Vol 1115 ◽  
pp. 39-42
Author(s):  
A.K.M. Nurul Amin ◽  
A.A. Che Omar ◽  
M.A. Mohammed Kamal ◽  
Mahmoud M.A. Nassar ◽  
N.F. Mohd Zaib ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Gas Turbines ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Ductile Regime Machining ◽  
Micro End Milling ◽  
Tungsten Carbide Tool

Soda lime glass is widely used in optics, chemical apparatus, camera lens, micro gas turbines, light bulbs etc. on account of its high hardness, corrosion resistance, and excellent optical properties. These require high dimensional accuracy and flawless surface finish. However, soda lime glass is inherently brittle leading to subsurface crack propagation and fracture which compromise its functionality. To avoid these defects, the machining needs to be performed under ductile mode conditions. Therefore, this research investigates the viability and requisite conditions for achieving ductile regime machining (DRM) in high speed micro-end milling of soda lime glass. Machining was performed at high cutting speeds (30,000 to 50,000 rpm), feed rate (5 to 15 mm/min), and depth of cut (3 to 7 μm). A surface profilometer was then used to measure the surface roughness and a scanning electron microscope (SEM) used to scrutinize the resultant machined surfaces. The results demonstrate that ductile streaks and rounded gummy chips (without sharp or jagged edges) are produced in all runs. In addition, there are no subsurface cracks and the minimum surface roughness attained is 0.08μm. These indicate that DRM of soda lime glass is obtainable using high-speed micro end milling in a conventional end mill with tungsten carbide inserts.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

An Experimental Study on Microcutting of Soda-Lime Glass by Milling Process

2010 ◽  
Vol 447-448 ◽  
pp. 116-120
Author(s):  
Muhammad Arif ◽  
Mustafizur Rahman ◽  
Yoke San Wong
Keyword(s):  
Free Surface ◽  
End Milling ◽  
Cutting Speed ◽  
Soda Lime ◽  
Milling Process ◽  
Dominant Factor ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Brittle Ductile Transition ◽  
Radial Depth

Glass is an important engineering material. It is widely used in semiconductor, optical, micro-electronics and many other fields. However, glass is not amenable to machining with conventional approach because of its low fracture toughness. To achieve high quality surface finish on optical components, glass must be machined in ductile mode. Compared to single point cutting processes, end-milling can achieve improved material removal rate in machining fracture free surface on brittle material. This paper presents the results of an experimental investigation into microcutting of glass by end-milling. Side-cutting tests have been performed on soda-lime glass workpiece at multiple feeds and radial depth of cuts to obtain fracture free machined surface. The tests were designed to investigate the effect of feed per edge and radial depth of cut on the cutting mechanism at low cutting speed. Experimental results indicate that feed per edge is the most dominant factor that dictates the occurrence of brittle-ductile transition point in the milling process of glass. It has been proved experimentally that fracture free surface can be machined on glass at high radial depth of cut if the feed per edge is sufficiently small.

scholarly journals Study The Effect of Process Parameters of CNC Milling Surface Generation Using Al-alloy 7024

2019 ◽  
Vol 12 (3) ◽  
pp. 103-112
Author(s):  
Nareen Hafidh Obaeed
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Surface Finish ◽  
Feed Rate ◽  
Spindle Speed ◽  
Surface Generation ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Cnc Milling ◽  
Tool Diameter

A wonderful unique research developments in modeling surface roughness and optimization of the predominant parameters to get a surface finish of desired level since only suitable selection of cutting parameters can get a better surface finish, so the objective of this work is to study the milling process parameters which include tool diameter, feed rate, spindle speed, and depth of cut resulting in optimal values of the surface roughness during machining AL-alloy 7024. The machining operation implemented on XK7124 3-axis CNC milling machine. The effects of the selected parameters on the chosen characteristics have been accomplished using Taguchi’s parameter design approach. The parameters considered are – depth of cut with two levels (0.2, 0.5 mm), tool diameter with two levels (6, 8 mm), spindle speed with two levels (1000, 2500 rpm), and finally feed rate with two levels (200, 500 mm/min). Analysis of the results showed that the optimal settings for low values of surface roughness are large tool diameter (8 mm), high spindle speed (2500 r.p.m), low feed rate (200 mm/min) and high depth of cut (0.5 mm). Response Table for mean of surface roughness showed that tool diameter has the most effected factors (rank one) followed by feed rate (rank two) then depth of cut which is the third effected factors and finally spindle speed with the less effected factors of surface roughness (rank four).

Effect of Cutter Diameters on Surface Roughness Attained in High Speed End Milling of Soda Lime Glass

2015 ◽  
Vol 1115 ◽  
pp. 51-54 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
A.A. Che Omar ◽  
M.A.Mohammed Kamal ◽  
Mahmoud M.A. Nassar ◽  
N.F. Mohd Zaib ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
End Mill ◽  
Machined Surface ◽  
Ductile Mode ◽  
Ductile Regime Machining ◽  
Brittle Fractures

Soda lime glass is used extensively in camera lens, micro gas turbines, light bulbs, tablewares, optics, and chemical apparatus owing to its high hardness, excellent optical properties, and good corrosion and chemical resistance. Such applications of soda lime glass demand high machining and finishing precision. On the other hand, machining of glass poses significant challenges due to its inherent brittleness. The process of removal of material from glass, if not done in ductile mode, can generate subsurface cracks and brittle fractures which have adverse effects on its functionality. This research investigates the high speed micro-end milling of soda lime glass in order to obtain ductile regime machining. It has been found by other researchers that ductile mode machining can avoid sub-surface cracks and brittle fractures. However, in ductile mode machining, the gummy chips settle permanently on the machined surface affecting adversely the surface finish. In order to avoid such chip settlement, compressed air was directed using a special air delivery nozzle to blow away the resultant gummy chips, thereby preventing them from settling on the machined surface. Response surface methodology (RSM) and a commercial NC end mill were used to design and perform the machining runs, respectively. Machining was done using: high spindle speeds from 30,000 to 50,000 rpm, feed rates from 5 to 15 mm/min, and depth of cuts from 3 to 7 μm. Three different diameter carbide tools were used: 0.5, 1, and 2 mm. A surface profilometer was used to analyze the surface roughness of the resultant machined surface. Subsequently, the data was used for finding the best combination of cutting parameters required to obtain the lowest surface roughness. The results demonstrate that high speed machining is a viable option for obtaining ductile regime machining and generating machined surfaces with very low surface roughness in the range of 0.08μm – 0.22 μm, using 0.5 mm carbide end mill cutter.

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