Abstract:The aim of this paper is to investigate the effect of cutting speed and uncut chip thickness on cutting performance. A Finite Element Method (FEM) based on the ABAQUS explicit software which involves Johnson-Cook material mode and Coulombs friction law was used to simulate of High Speed Machining (HSM) of AISI 1045 steel. In this simulation work, feed rate ranging from 0.05 mm/rev to 0.13 mm/rev and cutting speed ranging from 200 m/min to 600 m/min at three different cutting speeds were investigated. From the … Show more
“…As cutting speed increases, friction force and strain rate in the primary and secondary deformation zone increase, so an increase in cutting temperature is observed. 21,22 The increased cutting temperature reduces the built-up edge and increases the surface quality. Additionally, it was thought that the heating effect also contributes to the improvement of machining stability.…”
Section: Resultsmentioning
confidence: 99%
“…The results were consistent with the previous studies in the literature. 7–9,20,22 Figure 7.Frequency response function in (a) Conventional turning (b) Magnetic assisted turning (0.51 T).…”
Several methods have been developed in order to improve the traditional machining processes and machining outputs. In this study, the effect of the magnetic field on the turning process was investigated. AISI-4140 was machined with different cutting speeds and magnetic flux density magnitudes. The magnetic field was generated with neodymium magnets. Machining stability, surface roughness, and maximum cutting temperature were measured. Additionally, chip shapes were examined. The machining stability was determined by measuring the vibration amplitude and other vibrational parameters (natural frequency, stiffness, and damping coefficients). Conventional turning and magnetic assisted turning were performed under the same cutting parameters consecutively, and the results were compared. According to the results, it was observed that neodymium magnets attached to the cutting tool improve machining stability and damping properties. Surface roughness was decreased between 6%–10% in magnetic assisted turning. Furthermore, it has been observed that the maximum cutting temperatures have been increased between 10%–45% in the magnetic assisted machining. Besides, it can be said that magnets contribute to improving chip control by collecting the chips on them while machining AISI-4140 steel.
“…As cutting speed increases, friction force and strain rate in the primary and secondary deformation zone increase, so an increase in cutting temperature is observed. 21,22 The increased cutting temperature reduces the built-up edge and increases the surface quality. Additionally, it was thought that the heating effect also contributes to the improvement of machining stability.…”
Section: Resultsmentioning
confidence: 99%
“…The results were consistent with the previous studies in the literature. 7–9,20,22 Figure 7.Frequency response function in (a) Conventional turning (b) Magnetic assisted turning (0.51 T).…”
Several methods have been developed in order to improve the traditional machining processes and machining outputs. In this study, the effect of the magnetic field on the turning process was investigated. AISI-4140 was machined with different cutting speeds and magnetic flux density magnitudes. The magnetic field was generated with neodymium magnets. Machining stability, surface roughness, and maximum cutting temperature were measured. Additionally, chip shapes were examined. The machining stability was determined by measuring the vibration amplitude and other vibrational parameters (natural frequency, stiffness, and damping coefficients). Conventional turning and magnetic assisted turning were performed under the same cutting parameters consecutively, and the results were compared. According to the results, it was observed that neodymium magnets attached to the cutting tool improve machining stability and damping properties. Surface roughness was decreased between 6%–10% in magnetic assisted turning. Furthermore, it has been observed that the maximum cutting temperatures have been increased between 10%–45% in the magnetic assisted machining. Besides, it can be said that magnets contribute to improving chip control by collecting the chips on them while machining AISI-4140 steel.
“…Fenomena ini dapat ditemukan pada semua jenis mata pisau TC yang diuji. Laju bilah per putaran yang semakin besar mengindikasikan massa MDF yang dipotong per putaran semakin besar sehingga suhu pemotongan menjadi lebih tinggi (Sulaiman et al 2014). Suhu pemotongan yang tinggi dapat mengakibatkan bahan pelapis teroksidasi dan mengelupas dari permukaan substrat pisau TC yang pada akhirnya akan meningkatkan keausan (Guimarães et al 2022).…”
The scarcity and high cost of high-quality sawn timber has resulted in the switching of furniture industry to using composite wood such as medium density fiberboard (MDF) as the raw material for its products. One of the factors that affect production costs and product quality in the furniture industry is the quality of the cutting tool used in the cutting operation. The quality of the cutting tool could be improved through the addition of coatings on the surface of cutting tool (surface coating). The purpose of this study was to determine the life time of AlCrN, TiAlN, and TiN coated tungsten carbide (TC) tools in cutting MDF. Cutting operations were performed on a computer numerical control (CNC) router machine at feed per revolution (Frev) of 0,10, 0,15, 0,20, and 0,30 mm/rev. The TC cutting tool life was determined based on its wear and was calculated using the Taylor tool life formula. The results showed that coated TC cutting tool provided a better wear resistance and longer life than uncoated TC cutting tool. The low of Frev set in cutting MDF resulted in a lower wear and longer life of cutting tool. AlCrN coated TC cutting tool provided the best wear resistance and longest life, thus it promising to be developed and used in cutting MDF.
Keywords: coated cutting tool, medium density fiberboard, surface coating, tool life, wear
“…On the other hand, the 'smaller is better' normalization model (Equation 8) was adopted for the average surface roughness. The equations are adopted from Kiswanto et al (2019) and Sulaiman et al (2014):…”
This study evaluates CNC milling parameters (spindle speed, depth of cut, and feed rate) on medical-grade PMMA. A single objective analysis conducted showed that the optimal material removal rate (MRR) occurs at a spindle speed of 1250 rpm, a depth of cut of 1.2 mm, and a feed rate of 350 mm/min. The ANOVA showed that feed rate is the most significant factor towards the MRR, and spindle speed (11.83%) is the least contributing. The optimal surface roughness (Ra) occurred at spindle speed of 500 rpm, depth of cut of 1.2 mm, and feed rate of 200 mm/min. The milling factors were insignificant. A regression analysis for prediction was also conducted. Further, a multi-objective optimization was conducted using the Grey Relational Analysis. It showed that the best trade-off between the MRR and the Ra could be obtained from a combination of 1250 rpm (spindle speed), 1.2 mm (depth of cut), and 350 mm/min (feed rate). The depth of cut was the largest contributor towards the grey relational grade (54.48%), followed by the feed rate (10.36%), and finally, the spindle speed (4.28%).
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