Effect of Tool Nose Radius and Machining Parameters on Cutting Force, Cutting Temperature and Surface Roughness – An Experimental Study of Ti-6Al-4V (ELI)

Dm, Shah; Bhavsar, Sanket N.

doi:10.1016/j.matpr.2020.03.163

Cited by 23 publications

(15 citation statements)

References 21 publications

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“…ANOVA test was conducted to assess contribution of parameters. Developed model was interfaced with particle swarm optimization to minimize responses (Shah and Bhavsar 2020). To understand impacts of cutting edge microgeometries on surface integrity, experimental were conducted for a varied range of cutting tool geometries and feeds.…”

Section: Literature Reviewmentioning

confidence: 99%

Impact of nose radius and machining parameters on surface roughness, tool wear and tool life during turning of AA7075/SiC composites for green manufacturing

Bhushan

2020

Mech Adv Mater Mod Process

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Green manufacturing demands least wastage. Minimum chip formation reduces adverse effect on environment. Nose radius has a major role in reducing development of chips. Selection of proper nose radius and machining parameters will reduce amount of chip, therefore protect the environment. In finish turning of Al alloy-SiC, nose radius wear mainly affect the surface feature of the final product. It is owing to the direct contact between the area of tool nose and the SiC particles during turning. This paper is focused on influence of tool nose radius and machining parameters on surface quality of AA7075/15 wt.% SiC (20-40 μm) composites and tool life of tungsten carbide inserts while dry turning. Response surface method (RSM) was utilized to find the roughness and tool life under numerous turning situations. Considering the single objective optimization of turning parameters, minimum roughness of 2.088 μm, was achieved at nose radius of 1.2 mm and maximum tool life of 6.72 min, was obtained at nose radius of 0.4 mm. Multi objective optimization by desirability analysis for minimum roughness and the maximum life of tool has shown that suitable value of nose radius is 0.4 mm. Multi objective optimization of both roughness of surface and life of tool results in 1.81% increase in surface roughness and 10.11% decrease in tool life. Abrasion was mainly found to be responsible for wear of tungsten carbide inserts, while turning of AA7075/15 wt.% SiC (20-40 μm) composites. Novelty of this research work is that so far no one has investigated impact of nose radius and machining parameters on surface roughness, tool wear and tool life during turning of AA7075/15 wt.% SiC composites. Outcome of this research work will be useful for vehicle, aeroplane, space and ship industry.

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Section: Literature Reviewmentioning

confidence: 99%

Impact of nose radius and machining parameters on surface roughness, tool wear and tool life during turning of AA7075/SiC composites for green manufacturing

Bhushan

2020

Mech Adv Mater Mod Process

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“…The levels of cutting parameters are selected based on previous literature and tool manufacturer recommendation as cutting speed (v) of 70-140-210 m/min, feed (f) of 0.1–0.15–0.2 mm/rev and depth of cut (d) of 0.1–0.2–0.3 mm, respectively. 21,22,24,25 The MQL setup (DROPSA, Italy) was utilized to deliver the LRT 30 iron-aluminium mineral oil into the cutting zone. The LRT 30 oil hols good anti-corrosion characteristics and it is beneficial for the machining environment concern.…”

Section: Scheme Of Experimentationmentioning

confidence: 99%

“…Singh et al 23 observed that 1.5% weight concentration of graphene in canola oil–based MQL outperformed over conventional synthetic fluid during surface grinding of Ti-6Al-4V ELI alloy for tribological application. Shah and Bhavsar 24 studied the effect of nose radius and cutting parameters on cutting temperature, surface roughness and cutting force during turning Ti-6Al-4V ELI alloy. Mathematical models are developed and optimized through particle swarm optimization (PSO) to minimize the responses.…”

Section: Introductionmentioning

confidence: 99%

Investigation on surface roughness, tool wear and cutting power in MQL turning of bio-medical Ti-6Al-4V ELI alloy with sustainability

Rajan

Sahoo

Routara

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Ti-6Al-4V ELI (Grade 23) is highly recommended for bio-materials and due to its low thermal conductivity and chemically reactive properties, machinability is poor. Thus the current work emphasized on the selection of appropriate cooling technique and optimal cutting parameters for machining of Ti-6Al-4V ELI alloy with sustainability analysis for surface roughness, flank wear and cutting power. Initially, the cutting performances under dry, flood and MQL environments are compared and MQL is observed to better performed. At lower speed (70 m/min), MQL exhibited 26.38% and 19.69% lesser surface roughness relative to dry and flood cooling individually. At the same cutting condition, MQL assisted cutting resulted in lower flank wear relative to dry (157. 33%) and flood cooling (40%). Further, a detailed investigation has been made under MQL through Taguchi L18 design of experiments. The major mechanisms for flank wear are found to be abrasion, chipping and notch wear. Optimal data set through Grey relational analysis is found to be v1 (70 m/min), f1 (0.1 mm/rev) and d1 (0.1 mm) and improved. Quadratic regression model is found to be significant for prediction of responses. Sustainability Pugh matrix assessment revealed that MQL environment enhanced the economical, technological as well as environmental and operator health aspects. Reduction of energy consumption by 53.96% and savings of carbon footprints by 68.46 kg of CO2 observed under MQL at optimal conditions and thus saves manufacturing cost.

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“…Shi [10] and Qu [11] established a mathematical model of cutting temperature and cutting force to prove the correlation between cutting temperature and cutting parameters. Shah et al [12] studied the influence of cutting parameters on the cutting temperature of Ti-6Al-4V cutting process through particle swarm optimization algorithm. Turkes et al [13] used the finite element analysis to calculate the cutting parameters, and found that the temperature distribution of cutting tools and processing materials through the parameters.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Coupling Characteristics of Cutting Heat and Cutting Vibration Under Different Tool Wear States

et al. 2021

Preprint

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The thermo-mechanical-vibration coupling characteristics of turning system has always been an important research topic in the field of machining, and the material, states and performance of cutting tools will directly affect this coupling characteristics. In this paper, a synchronous testing system for cutting temperature and cutting vibration is built to collect the cutting temperature and cutting vibration near the tip of three worn tools D1 (new blade), D2 (moderately worn blade) and D3 (severely worn blade). Based on the test data and the grey correlation theory, the coupling characteristics of cutting temperature rise and cutting vibration of tools in different wear states are analyzed. Based on the experimental data and least square method, (1) the regression model of cutting temperature rise about cutting vibration and cutting parameters (2) the regression model of cutting vibration about cutting temperature rise and cutting parameters have been established respectively. The undetermined parameters and correlation coefficients are obtained by MATLAB software programming. The research show that the coupling of cutting heat and cutting vibration of tools D1 and D2 is one-way coupling, that is, cutting vibration significantly affects cutting heat, but cutting heat has little effect on cutting vibration, while the coupling of cutting heat and cutting vibration of tool D3 is a bidirectional coupling.

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Effect of Tool Nose Radius and Machining Parameters on Cutting Force, Cutting Temperature and Surface Roughness – An Experimental Study of Ti-6Al-4V (ELI)

Cited by 23 publications

References 21 publications

Impact of nose radius and machining parameters on surface roughness, tool wear and tool life during turning of AA7075/SiC composites for green manufacturing

Impact of nose radius and machining parameters on surface roughness, tool wear and tool life during turning of AA7075/SiC composites for green manufacturing

Investigation on surface roughness, tool wear and cutting power in MQL turning of bio-medical Ti-6Al-4V ELI alloy with sustainability

Experimental Study on Coupling Characteristics of Cutting Heat and Cutting Vibration Under Different Tool Wear States

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