Abstract:The problem of machining titanium is one of the ever-increasing magnitudes due to its low thermal conductivity and work-hardening characteristic. In the present work, experimental studies have been carried out to obtain the optimum conditions for machining titanium alloy. The effect of machining parameters such as speed, feed, depth of cut and back rake angle on cutting force, and surface roughness were investigated. The significance of these parameters, on cutting force and surface roughness, has been establi… Show more
“…A new optimization approach called the multivariate robust parameter design (MRPD) was applied by Paiva et al [8] with the target of minimal surface roughness during hard turning of AISI 52100 steel with coated mixed ceramic inserts. In a recent study, Satyanarayana et al [9] used the ANOVA to evaluate the significance of cutting parameters and rake angle on cutting force and surface roughness obtained in hard turning of titanium alloy.…”
The increasing industrial demand for hard materials and their wide range of applications requires significant investigations to improve their machinability. Therefore, the current study addresses cutting forces and surface roughness during hard turning of AISI 52100 steel (59 hardness Rockwell C (HRC)) using ceramic tool. Turning experiments were held out by varying cutting speed, depth of cut, feed rate, and tool nose radius. For so doing, a central composite design (CCD) was adopted including 30 tests. Cutting forces and surface roughness were modeled using response surface methodology (RSM). The effects of each input parameter on output responses were investigated using analysis of variance (ANOVA) and response surface graphics. The findings of this study demonstrated that the force components were significantly influenced by depth of cut, followed by feed rate with a lower degree. Likewise, the negative result of the small undeformed chip thickness on surface roughness was reduced by the employment of large nose radius. Conclusively, a correlation between cutting force behavior and surface roughness was established and confirmed by the threedimensional topographic maps of the machined surfaces. The RSM was utilized to define the optimal machining parameters.
“…A new optimization approach called the multivariate robust parameter design (MRPD) was applied by Paiva et al [8] with the target of minimal surface roughness during hard turning of AISI 52100 steel with coated mixed ceramic inserts. In a recent study, Satyanarayana et al [9] used the ANOVA to evaluate the significance of cutting parameters and rake angle on cutting force and surface roughness obtained in hard turning of titanium alloy.…”
The increasing industrial demand for hard materials and their wide range of applications requires significant investigations to improve their machinability. Therefore, the current study addresses cutting forces and surface roughness during hard turning of AISI 52100 steel (59 hardness Rockwell C (HRC)) using ceramic tool. Turning experiments were held out by varying cutting speed, depth of cut, feed rate, and tool nose radius. For so doing, a central composite design (CCD) was adopted including 30 tests. Cutting forces and surface roughness were modeled using response surface methodology (RSM). The effects of each input parameter on output responses were investigated using analysis of variance (ANOVA) and response surface graphics. The findings of this study demonstrated that the force components were significantly influenced by depth of cut, followed by feed rate with a lower degree. Likewise, the negative result of the small undeformed chip thickness on surface roughness was reduced by the employment of large nose radius. Conclusively, a correlation between cutting force behavior and surface roughness was established and confirmed by the threedimensional topographic maps of the machined surfaces. The RSM was utilized to define the optimal machining parameters.
“…Then this amplifier converts the analog signal to digital signal that is incessantly recorded by means of the data acquisition system connected to the amplifier, and is put into the computer finally. 29 Figure 4.3D structure drawing of machining system of UAT.…”
Section: Machining System Of Uatmentioning
confidence: 99%
“…Then this amplifier converts the analog signal to digital signal that is incessantly recorded by means of the data acquisition system connected to the amplifier, and is put into the computer finally. 29 In the experiment, the Switzerland KISTLER 9257B type quartz three-component piezoelectric dynamometer and 5070 type multichannel amplifier, together with the France MiCROMEASUR2 type three dimensional (3D) surface profiler and Japan VHX-1000 E type super depth of field 3D display system were employed to measure cutting forces, surface roughness, surface topography, tool wear and chip shape, respectively. The operational machining system of UAT is shown in Figure 5.…”
Section: Machine Tool and Measurement Systemmentioning
The aim of this paper is to present an experimental investigation of the cutting forces, surface quality, tool wear and chip shape in ultrasonic vibration assisted turning (UAT) of 304 austenitic stainless steel (ASS 304) in comparison to conventional turning (CT). This study focuses on the solution of the machining difficulties of ASS 304 and high demands for the processing quality and efficiency. The machining system of UAT is schemed out to assure the desired machining effect by utilizing ultrasonic vibration method. Meanwhile, a series of systematic experiments are performed with and without ultrasonic vibration using the designed machining system of UAT with cemented carbide coated cutting tool. The results obtained from the UAT and CT experiments demonstrate that the cutting effect of UAT is much better than that of CT. Furthermore, the results of this research indicate that the ultrasonic amplitude, cutting speed, feed rate and depth of cut in UAT of ASS 304 have visible influence on the cutting forces, surface quality and tool wear. And reasonable selection of various technological variables in UAT can obtain lower cutting forces, more superior surface roughness, advantageous surface topography, slow and less tool wear, thin and smooth chips.
“…22,23 Its unique difference from conventional machining is that it takes advantage of the vibrations produced by the device or machine tool to add vibrations to the workpiece or drill that are regular or easily controlled. 24–26 The application of vibration has changed conventional machining theory, turning a continuous cutting process into a pulse cutting process that is capable of achieving processing effects beyond those of common drilling. 27–29…”
When difficult-to-machine materials are drilled, chips are produced, and these chips are difficult to control during the drilling process. Due to the limitations of conventional drilling, materials are drilled by ultrasonic-vibration-assisted technology. In this paper, the kinematics of ultrasonic-vibration-assisted drilling are first analyzed and the relevant equations are established. The characteristic thicknesses of chips are then studied, and the drilling paths for different phases and thicknesses of the chips are analyzed. The condition of complete geometric chipbreaking in the ultrasonic-vibration-assisted drilling process is examined, and a regional map of chipbreaking is presented, which in theory allows chips to be controlled. Chips produced in ultrasonic-vibration-assisted drilling with different parameters are compared in a series of experiments. The chipbreaking condition is studied in more detail, and the chips produced by drilling difficult-to-machine materials are effectively controlled. Furthermore, the results of this study show that a reasonable selection of parametric variables in ultrasonic-vibration-assisted drilling results in thin and smooth chips, less tool wear, and superior surface roughness.
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