Calculation and Estimation of Surface Roughness and Energy Consumption in Milling of 6061 Alloy

Öztürk, Burak; Kara, Fuat

doi:10.1155/2020/5687951

Cited by 44 publications

(19 citation statements)

References 30 publications

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“…Figure 6 shows the main effects plot with the mean Spk value graphically; the magnitude of each gradient indicates how sensitive each factor was to the Spk; the main effects plot is a frequently used method for Taguchi analysis ( [16,34]). When fluence was changed from 0.050 to 0.099 J/cm 2 , Spk increased; the increase was more rapid from 0.099 J/cm 2 to 0.149 J/cm 2 .…”

Section: Resultsmentioning

confidence: 99%

“…Recently, various statistical and analytical techniques, e.g. regression, orthogonal arrays, Taguchi design of experiments (DOE) and analysis of variance (ANOVA), are used to compare the effects parameters have on the operation output and statistically examine the significance of each parameter [16]. They are simple tools to understand multi-variate behaviour compared to finite element approaches which require high computational input and expertise.…”

Section: Introductionmentioning

confidence: 99%

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Understanding the surface integrity of laser surface engineered tungsten carbide

Hazzan

Pacella

See

2021

Int J Adv Manuf Technol

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The study investigated the effect of fibre laser processing (1060 nm, 240-ns pulse duration) on the surface integrity of tungsten carbide (WC). The induced surface damage ranged from crack formation, porosity, balling, to spherical pores; the severity and presence of each were dependent on the laser parameters selected. The influence of fluence (0.05–0.20 J/cm2), frequency (5–100 kHz), feed speed (250–2500 mm/s) and hatch distance (0.02–0.06 mm) on 2D and 3D surface roughness were analysed using the Taguchi technique. Fluence, frequency, and the interaction effect of these were the most influential factors on the surface integrity; from this a linear model was generated to predict the surface roughness. The model performed best at moderate to medium level of processing with an error between 1 and 10 %. The model failed to predict the material response as accurately at higher fluences with percentage errors between 15 and 36 %. In this study, a crack classification system and crack density variable were introduced to estimate the number of cracks and crack type within a 1-mm2 area size. Statistical analysis of variance (ANOVA) found that fluence (63.49%) and frequency (29.38%) had a significant effect on the crack density independently but not the interaction of both. The crack density was minimised at 0.149 J/cm2 and 52.5 kHz. To the author’s knowledge, for the first time, a quantitative analysis of the crack formation mechanism for brittle materials is proposed (post laser processing).

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Understanding the surface integrity of laser surface engineered tungsten carbide

Hazzan

Pacella

See

2021

Int J Adv Manuf Technol

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“…This method is commonly used in the optimisation of machining parameters. 36–43 The experimental plan was developed in two stages. The final goal is to determine the best strategy and parameters to minimise the arithmetical mean roughness value ( R a ).…”

Section: Methodsmentioning

confidence: 99%

Toolpath and machining parameters optimisation of the cavities of a knee prosthesis tibial insert

Lopes

Completo

Davim

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The main purpose of this paper is to demonstrate the applicability of conventional cutting tools in the machining of a custom tibial insert of a knee prosthesis. This study also aims to reduce the roughness and minimise the production time. In this work, the optimisation of cutting strategies and parameters was achieved through the design and construction of a test-part containing the most important complex surfaces of the femoral cavities, the focus of the study. The milling was carried out in accordance with the Design Of Experiment and the Taguchi method and was performed in two stages to reduce the number of analysed factors. The achieved parameters are applied to the machining of a modelled tibial insert made of UHMWPE, using a NC machine with three axes. The initial parameters studied were the cutting method, axial and radial depth of cut, the direction of the feed and the feed rate. Three strategies were studied: two Blend, resulting in radial and spiral toolpaths, and one Parallel. According to the spiral strategy, an arithmetical mean roughness of Ra = 1.1 µm was obtained, representing an improvement of 45% relatively to the initial phase value of 2.0 µm, with the Parallel toolpath. An overall improvement of 34% in time efficiency of the finishing operation was achieved after changing the machine settings. This study supports the conclusion that high-speed milling is an expeditious process to produce customised tibial inserts.

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“…Surface roughness, which is an unavoidable phenomenon at machining, is usually strictly required when the processed materials are applied in structural components subjected to cyclic loads [11]. Surface roughness is usually characterised by an average geometric parameter, namely arithmetic mean roughness (Ra) [12]. Moreover, the accuracy and efficiency of roughness measurements are important to the modern industry [6].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation into the Effect of Surface Roughness and Mechanical Properties of 3D-Printed Titanium Ti-64 ELI after Heat Treatment

Lebea¹,

Ngwangwa²,

Desai³

et al. 2021

Preprint

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The initial stability after implantology is paramount to the survival of the dental implant and the surface roughness of the implant plays a vital role in this regard. The characterisation of surface topography is a complicated branch of metrology, with a huge range of parameters available. Each parameter contributes significantly towards the survival and mechanical properties of 3D-printed specimens. The purpose of this paper is to experimentally investigate the effect of surface roughness of 3D-printed dental implants and 3D-printed dogbone tensile samples under areal height (Ra) parameters, amplitude parameters (average of ordinates), skewness (Rsk) parameters and mechanical properties. During the experiment, roughness values were analysed and the results showed that the skewness parameter demonstrated a minimum value of 0.596%. The 3D-printed dental implant recorded Ra with a 3.4 mm diameter at 43.23% and the 3D-printed dental implant with a 4.3 mm diameter at 26.18%. Samples with a complex geometry exhibited a higher roughness surface, which was the greatest difficulty of additive manufacturing when evaluating surface finish. The results show that when the ultimate tensile stress (UTS) decreases from 968.35 MPa to 955.25 MPa, Ra increases by 1.4% and when UTS increases to 961.18 MPa, Ra increases by 0.6%. When the cycle decreases from 262142 to 137433, Ra shows that less than a 90.74% increase in cycle is obtained. For 3D-printed dental implants, the higher the surface roughness, the lower the mechanical properties, ultimately leading to decreased implant life and poor performance.

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Calculation and Estimation of Surface Roughness and Energy Consumption in Milling of 6061 Alloy

Cited by 44 publications

References 30 publications

Understanding the surface integrity of laser surface engineered tungsten carbide

Understanding the surface integrity of laser surface engineered tungsten carbide

Toolpath and machining parameters optimisation of the cavities of a knee prosthesis tibial insert

Experimental Investigation into the Effect of Surface Roughness and Mechanical Properties of 3D-Printed Titanium Ti-64 ELI after Heat Treatment

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