Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Aamir, Muhammad; Giasin, Khaled; Tolouei‐Rad, Majid; Din, Israr Ud; Hanif, Muhammad Imran; Kuklu, Uğur; Pimenov, Danil Yurievich; İkhlaq, Muhammad

doi:10.3390/met11060854

Cited by 22 publications

(13 citation statements)

References 34 publications

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“…Furthermore, Analysis of variance (ANOVA) was utilized to establish the percentage contribution of each input parameter regarding surface roughness and material removal rate. p-Values estimated at more than 0.05 or 5% were considered insignificant because ANOVA in this research was run with a confidence interval of 95%, in alignment with previous studies [24,[44][45][46].…”

Section: Design Of Experimentssupporting

confidence: 61%

Analysis and Optimization of Process Parameters in Abrasive Waterjet Contour Cutting of AISI 304L

Llanto

Vafadar

Aamir

et al. 2021

Metals

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Abrasive waterjet machining is applied in various industries for contour cutting of heat-sensitive and difficult-to-cut materials like austenitic stainless steel 304L, with the goal of ensuring high surface integrity and efficiency. In alignment with this manufacturing aspiration, experimental analysis and optimization were carried out on abrasive waterjet machining of austenitic stainless steel 304L with the objectives of minimizing surface roughness and maximizing material removal rate. In this machining process, process parameters are critical factors influencing contour cutting performance. Accordingly, Taguchi’s S/N ratio method has been used in this study for the optimization of process parameters. Further in this work, the impacts of input parameters are investigated, including waterjet pressure, abrasive mass flow rate, traverse speed and material thickness on material removal rate and surface roughness. The study reveals that an increasing level of waterjet pressure and abrasive mass flow rate achieved better surface integrity and higher material removal values. The average S/N ratio results indicate an optimum value of waterjet pressure at 300 MPa and abrasive mass flow rate of 500 g/min achieved minimum surface roughness and maximum material removal rate. It was also found that an optimized value of a traverse speed at 90 mm/min generates the lowest surface roughness and 150 mm/min produces the highest rate of material removed. Moreover, analysis of variance in the study showed that material thickness was the most influencing parameter on surface roughness and material removal rate, with a percentage contribution ranging 90.72–97.74% and 65.55–78.17%, respectively.

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Section: Design Of Experimentssupporting

confidence: 61%

Analysis and Optimization of Process Parameters in Abrasive Waterjet Contour Cutting of AISI 304L

Llanto

Vafadar

Aamir

et al. 2021

Metals

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“…The process parameters, such as feed rate, spindle speed, cutting fluid, tool diameter, and chip formation play a key role in hole quality [3,4]. Similarly, an appropriate selection of machine setup and cutting tools during drilling operations is essential to avoid rapid tool wear and low-quality holes [5][6][7].…”

Section: Introductionmentioning

confidence: 99%

Assessment of Hole Quality, Thermal Analysis, and Chip Formation during Dry Drilling Process of Gray Cast Iron ASTM A48

Habib

Sharif

Hussain

et al. 2022

Eng

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The cutting parameters in drilling operations are important for high-quality holes and productivity improvement in any manufacturing industry. This study investigates the effects of spindle speed and feed rate on temperature, surface roughness, hole size, circularity, and chip formation during dry drilling of gray cast iron ASTM A48. The results showed that the temperature increased as spindle speed and feed rate increased. The surface roughness had an inverse relationship with the spindle speed and direct relation with the feed rate. Furthermore, hole size increased with increased spindle speed and decreased as the feed rate increased, while hole circularity decreased with increasing both the spindle speed and feed rate. The analysis of variance (ANOVA) indicated that the spindle speed had the highest percentage contribution of 56.24% on temperature, followed by the feed rate with 42.35%. The surface roughness was highly influenced by the feed rate and the spindle speed with 55% and 44.12%, respectively. While the hole size was highly influenced by the feed rate with a 74.18% percentage contribution, and the contribution of spindle speed was 21.36%. In addition, the feed rate has a percentage contribution of 70.82% on circularity, which is higher than the spindle speed of 24.26% percentage contribution. The results also showed that thick and discontinuous chips were generated at higher feed rates, while long continuous chips were produced at high spindle speeds.

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“…The machining process has been an essential part of the industry since the industrial revolution [1,2]. Milling is a broadly used machining process in various manufacturing industries [3].…”

Section: Introductionmentioning

confidence: 99%

Machining of Carbon Steel under Aqueous Environment: Investigations into Some Performance Measures

et al. 2022

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In this study, a new machining approach (aqueous machining) is applied for mill machining and its performance is compared with traditional wet machining. AISI 1020 steel is employed as the test material and Taguchi statistical methodology is implemented to analyze and compare the performance of the two machining approaches. The cutting speed, feed rate, and depth of cut were the machining parameters used for both types of machining, while the selected response variables were surface roughness and hardness. Temperature variations were also recorded in aqueous machining. Compared with wet machining, aqueous machining resulted in lower surface roughness (up to 13%) for the same operating conditions and about 14% to 16% enhancement in hardness due to the formation of finer pearlite, as revealed by the microstructure analysis. Compared to the parent unmachined surface, the hardness of machined surfaces was 24% to 31% higher in wet machining and 44% to 51% higher in aqueous machining. Another benefit of aqueous machining was the energy gain, which ranged from 718 to 8615.96 J. This amount of heat energy can be used as waste heat for preheating domestic hot water, running the organic Rankine cycle with waste heat and preheating the inlet saline water for desalination, vacuum desalination, etc. If successfully implemented in the future, this idea will provide a step towards achieving sustainable machining by saving lubricants and toxic wastes in addition to saving energy for secondary applications.

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Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Cited by 22 publications

References 34 publications

Analysis and Optimization of Process Parameters in Abrasive Waterjet Contour Cutting of AISI 304L

Analysis and Optimization of Process Parameters in Abrasive Waterjet Contour Cutting of AISI 304L

Assessment of Hole Quality, Thermal Analysis, and Chip Formation during Dry Drilling Process of Gray Cast Iron ASTM A48

Machining of Carbon Steel under Aqueous Environment: Investigations into Some Performance Measures

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