Effect of cutting edge modification on the tool flank wear in ultrasonically assisted turning of hardened steel

Farahnakian, Masoud; Keshavarz, Mohamad Ebrahim; Elhami, S.; Razfar, Mohammad Reza

doi:10.1177/0954405416640416

Cited by 24 publications

(7 citation statements)

References 34 publications

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“…The intermittent cutting of UAT reduced the tool contact time with the chip, reducing the heat conduction to the chip's tool face due to the chip's lower tool wear than CT. The authors found that applying vibration improved the surface finish compared to CT. Farahnakian et al 15 studied the flank wear of the WC tool with and without initial wear when machining the hardened alloy steel. The authors found that modified WC tools produced less flank wear than CT and UAT with ordinary carbide tools at cutting speeds well below the critical cutting speed.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation on the machining performance of AISI D2 tool steel during ultrasonic-assisted turning under dry and MQL conditions

Umasekar

John

2023

Proceedings of the Institution of Mechanical Engineers, Part E:

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Ultrasonic-assisted turning (UAT) is a hybrid machining method that improves difficult-to-cut materials’ machinability and surface integrity. Minimum quantity lubrication (MQL) is a cooling condition employed in metal cutting operations to improve machining performance and environmental sustainability. This article presents the experimental investigations on the effect of machining and vibration parameters and cooling conditions on the surface roughness (Ra), flank wear (Vb), and surface hardness (HV) during UAT of AISI D2 tool steel. Experiments were designed based on L36 orthogonal array. Two levels of spindle speeds, feed rates, depth of cut, and three levels of percentage intensity of ultrasonic power (PIUP) were employed, and two cooling conditions, like dry and MQL. Analysis of variance (ANOVA) was used to find the significant input parameters that affect each response. ANOVA output revealed that feed rate was the most influential factor on Ra, the PUIP is the dominant factor on HV, and spindle speed is the significant factor on Vb. Optimisation is performed to find optimal parameters as per Taguchi multi-response method. The optimal parameters are 450 rpm spindle speed, 0.05 mm/rev feed rate, 0.1 mm depth of cut, 100 PIUP and MQL cooling resulted in minimum surface roughness of 0.439 μm, maximum hardness of 283 HV and minimum flank wear of 168 μm. Flank wear morphology results showed that abrasion and chipping are the tool wear mechanism in dry UAT, whereas minor abrasion alone was found in MQL UAT compared to CT. Chip morphology study showed that UAT produced continuous spiral-type chips under both cooling conditions compared to CT. A novel design approach is implemented to design the UAT tool. Along with the UAT tool, MQL is also given to improve the machinability of D2 tool steel. This UAT tool can machine intricate metals with a critical cutting velocity of less than 75.4 m/min.

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Section: Introductionmentioning

confidence: 99%

Experimental investigation on the machining performance of AISI D2 tool steel during ultrasonic-assisted turning under dry and MQL conditions

Umasekar

John

2023

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…Related experiments resulted in patterns of dimple array and proved the performance of the presented process. Farahnakian et al 15 studied the surface roughness during the one-directional ultrasonic assisted turning. They presented a special tool with a modified cutting edge with a flexible fabrication process which resulted in various types of textures on machined surfaces.…”

Section: Introductionmentioning

confidence: 99%

Employment of ultrasonic assisted turning in the fabrication of microtextures to improve the surface adhesion of the titanium implant

Zamani

Farahnakian

Elhami

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Since the presentation of the cell adhesion concept, properties of the contact surface between osteoblasts and titanium implant and possible methods to enhance related characteristics have attracted much attention in orthopedic investigations. The creation of microtextures on the titanium implant is an important method to improve cell adhesion. This research includes the employment of Ultrasonic Assisted Turning (UAT) to create special microtextures on the titanium implant. Also, the developed interfacial ratio (Sdr) are analyzed to understand the effect of main surface characteristics on the adhesion behavior and parameters. Moreover, the effects of ultrasonic vibrations on Sdr are presented by theoretical relation and graphical modeling. Results showed micro dimples (textures) depth and width were a function of ultrasonic characteristics (amplitude and direction) and cutting speed of turning. Developed interfacial ratio (Sdr) was another surface parameter that improved by UAT (about 20% in geometrical simulations) while surface roughness did not change significantly by the application of UAT. SEM images show larger integrin and extended fibronectin of osteoblast which adhered to the textured surfaces. This result demonstrated the abilities of UAT to fabricate titanium implants with enhanced adhesion properties for osteoblast cells.

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“…Different traditional and modern techniques are nominated to enhance surface quality of the workpiece according to cost, time, workpiece material, and surface complexities demands. In recent decades, the vibration of a tool or workpiece is known as an efficient assistant technique in conventional [1][2][3][4][5][6][7][8][9][10][11][12][13] and non-conventional [14][15][16][17][18][19][20][21][22][23][24][25][26][27][28][29][30][31] machining processes. Vibratory and ultrasonic machining are two main non-conventional polishing processes, which are based on vibration phenomenon.…”

Section: Introductionmentioning

confidence: 99%

Surface roughness study of polyamide in nano-metric polishing using low-frequency acoustic energy

Beigmoradi

Vahdati

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Polymers have gained the attention of manufacturers due to their significant advantages such as low density, high corrosion resistance, and high humidity resistance. Producing high-precision polymeric components is one the most challenging issues especially in fabricating complex or micro-scale systems. Some of the machining techniques such as electro discharge machining (EDM) and electrochemical machining (ECM) cannot be employed for machining the non-conductive parts. Using abrasive particles is one of the best options for machining these types of materials. In this work, the capability of the acoustic energy for machining polyamide (PA) workpieces is studied. To this end, an experimental setup is installed and design of experiment (DoE) algorithm is employed to survey the effect of process parameters on surface roughness. Three parameters at three levels are considered as the effective factors of the process and the sensitivity of the surface roughness on the process factors is investigated. In the next step, a hybrid finite element/boundary element approach was used to discuss the relation of process parameters to the vibrational characteristics of the container, then the mechanism of the process was investigated employing the discrete element method. Finally, the surface topology of the optimal workpiece before and after the process was presented and compared. It was observed that acoustic energy can be considered as a vibration source of the container’s floor to provide kinetic energy for machining PA parts on the nano-metric scale. Moreover, it was found that the initial roughness of the workpiece and the chosen parameters play a crucial role in the machining process. Experimental results show that in this technique by selecting appropriate process factors the surface roughness can be reduced up to 50%.

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Effect of cutting edge modification on the tool flank wear in ultrasonically assisted turning of hardened steel

Cited by 24 publications

References 34 publications

Experimental investigation on the machining performance of AISI D2 tool steel during ultrasonic-assisted turning under dry and MQL conditions

Experimental investigation on the machining performance of AISI D2 tool steel during ultrasonic-assisted turning under dry and MQL conditions

Employment of ultrasonic assisted turning in the fabrication of microtextures to improve the surface adhesion of the titanium implant

Surface roughness study of polyamide in nano-metric polishing using low-frequency acoustic energy

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