FEM simulation for determining suitable parameters for dimple structure fabrication in turning process

Dali, Mohd Nor Azam Bin Mohd; Ghani, Jaharah A.; Haron, Che Hassan Che; Hassan, Shahid

doi:10.1504/ijmpt.2016.079199

Cited by 2 publications

(7 citation statements)

References 0 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Referring to Figure 1, the values for cutting speed and frequency were based on previous findings by Dali et al (2016), Chen et al (2018a), Greco et al (2009) and Kurniawan and Ko (2013). The values obtained from Figure 1 were to be used in Taguchi L 8 to ensure the range of values was tested efficiently and systematically.…”

Section: Methodsmentioning

confidence: 99%

“…The factors were represented as operating parameters for this research. As for the levels, the first level was based on optimum parameters acting as control parameters in this research for dimple fabrication, as shown in Figure 1, which had been determined by Dali et al (2016). Meanwhile, the second level was based on the gap values found (cutting speed = 2 m/min and frequency = 28 Hz; refer Figure 1) that were not being tested from previous research findings.…”

Section: Methodsmentioning

confidence: 99%

“…This was supported by Chen et al (2018b), who stated that frequency and cutting speed influence the surface texture formation. Because of the low frequency which could be produced by DATT (maximum frequency: 28 Hz), the range of cutting speed was limited to the suggestion by Dali et al (2016) and others as below. Figure 1 shows the possible range for determining suitable cutting speed and frequency that were later used in the Taguchi method.…”

Section: Machining Parametersmentioning

confidence: 99%

“…It is undeniable that this process has its own drawbacks such as low production speed compared to other processes, such as micro coining, laser-based or etching techniques. Nevertheless, other researchers have recommended turning process for dimple production albeit its drawbacks (Nasir et al, 2019;Hassan et al, 2017;Qu et al, 2018;Ghani et al, 2018Ghani et al, , 2019Dali et al, 2016). DATT was developed in-house mainly to produce vibrations for the cutting tool to fabricate dimples on the material surface.…”

Section: Machining Testmentioning

confidence: 99%

“…Previously, Dali et al (2016) had determined the optimum parameters for fabrication of dimple by using DATT. In this current research, Dali’s findings have been used as the control parameter for dimple fabrication.…”

Section: Introductionmentioning

confidence: 99%

See 4 more Smart Citations

Characteristics of dimple structure on aluminium silicon alloy fabricated using turning machine

Nasir

Ghani

Kasim

et al. 2021

ILT

View full text Add to dashboard Cite

Purpose This research aims to present the characteristics of dimple structure which was fabricated using a turning machine, where the characteristics include sizes, shapes, area ratio and aspect ratio. This research aims at filling the gap in the machining parameters of previous research in producing dimple by using turning process with the aid of dynamic assisted tooling for turning (DATT). In producing dimple, a carbide insert grade H1 was used on a hypereutectic aluminium silicon alloy (A390) material. Dimple has many advantages such as for reducing friction coefficient, load-carrying capacity and trap wear debris for sliding mechanical components. Design/methodology/approach There are seven machining parameters (cutting speed, feed rate, depth of cut, frequency, amplitude, rake angle, relief angle and nose radius) which have an influence on dimple produced. Taguchi method (orthogonal arrays L8) was used to conduct the experiment systematically and efficiently for these seven parameters. A carbide insert grade H1 was used as a cutting tool on a turning machine with the aid of DATT. The dimple structure was fabricated on a cylindrical rod hypereutectic aluminium silicon alloy (A390). A profilometer 3D Alicona infinite focus and an optical microscope equipped with Vis software were used to analyse the fabricated dimple structure. Findings Various shapes and sizes of ellipse dimples were produced in this research, including short and long drops with lengths in the range of 517.03–3,927.61 µm, widths of 565.15–1,039.19 µm, depths of 14.46–124.87 µm, area ratios of 5.05–25.65% and aspect ratios of 0.007%–0.111%. There were four experiments within the optimal area ratio range of 10%–20%, i.e. the second, third, seventh and eighth experiments. The width of these dimples was 895.95, 961.39, 787.27 and 829.22 µm, length was 826.26, 3163.13, 885.98 and 1026.65 µm, depth was 83.67, 84.19, 87.05 and 110.70 µm and area ratio was 15.12%, 13.14%, 14.79% and 12.70%. The surface roughness of textured surface was below 1 µm. In this research, the results obtained were similar with that of previous researchers on dimple structure related to tribology performance. Originality/value There exists machining parameters, namely, cutting speed and frequency, that were not used by previous research in producing dimple. These machining parameters (cutting speed and frequency) were used in this research to produce dimple via turning process with the aid of DATT using carbide insert grade H1. The turning process is an environmentally friendly process which is suitable for mass production for fabricating dimple structure as compared to most of the current methods which are widely used in fabricating dimple structure.

show abstract