Fundamentals of Metal Machining and Machine Tools

Boothroyd, G.

doi:10.1201/9780429114243

Cited by 117 publications

(79 citation statements)

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“…When these results were evaluated, it was observed that an increase in the amount of Al in these alloys (intermetallic phases (Mg 17 Al 12 and Al 8 Mn 5 )) (when 0.5 % Mn was kept fixed) could be effective on cutting force of these magnesium alloys [7][8][9][10][11][12][13][14][15][16]. From this point of view, it may be noted that the increase in cutting forces depending on cutting speed could occur due to dislocation build-up with chips in cutting edge [17][18][19][20][21][22][23]. The reason for this was the increase in cutting forces with the effect of intermetallic phases (Mg 17 Al 12 and Al 8 Mn 5 ) observed in the microstructure.…”

Section: Machining Propertiesmentioning

confidence: 99%

“…FBU formation increased on the cutting tool due to the effect of intermetallic phases between the cutting edge and sample surface contact point and also this caused an increase in the cutting forces ( Fig. 4) [17][18][19][20][21][22][23]. It can also be said that FBU formation in- creased with friction and temperature rise on the cutter surface due to an increase in cutting speed, and as a result of this, cutting forces also rose.…”

Section: Machining Propertiesmentioning

confidence: 99%

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Influence of Al content on machinability of AM series magnesium alloys

Akyüz¹

2018

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This study investigates the effects of Al (aluminium) amount in AM series magnesium alloys on mechanical properties and machinability (cutting forces). Changes in microstructure and mechanical properties and their effects on cutting forces were analysed depending on the increase in Al amount. For this reason, AM series magnesium alloys (AM20, AM40, AM60, and AM90) with varying amounts of Al % (from 2 to 9 %) were used in the study. It was observed that in AM series magnesium alloys (containing 0.5 % Mn), intermetallic phases found in microstructure (Mg17Al12 and Al8Mn5) improved the mechanical properties and lowered machinability by rising the cutting forces (Fc) depending on the increase in Al amount. Also, the surface roughness (Ra) of intermetallic phases was observed to have an impact on flank build-up-FBU and chip formation. While AM90 had the highest values in terms of mechanical properties and surface quality, AM20 had the lowest values. On the other hand, AM20 had the highest El% values and machinability properties.

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Section: Machining Propertiesmentioning

confidence: 99%

Section: Machining Propertiesmentioning

confidence: 99%

Influence of Al content on machinability of AM series magnesium alloys

Akyüz¹

2018

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“…Thanks to the high precision and quality of machined surfaces, it is possible to machine even very complex shapes which are most often used in the production of pressing tools. However, the main drawbacks are relatively slow material removal and energy intensity [1,2].…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM

et al. 2020

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The unconventional technology of wire electrical discharge machining is widely used in all areas of industry. For this reason, there is always an effort for efficient machining at the lowest possible cost. For this purpose, the following comprehensive study has been carried out to optimize the machining of the copper alloy Ampcoloy 35, which is particularly useful in plastic injection moulds. Within the study, a half-factor experiment of 25-1 with 10 axial points and seven central points of a total of 33 rounds was carried out, which was focused on the response monitoring of the input factors in the form of the machine parameters setup: gap voltage, pulse on time, pulse off time, discharge current, and wire speed. Based on the study of the response in the form of cutting speed and surface topography, their statistical models were created, while the optimal setting of machine parameters was determined to maximize the cutting speed and minimize the topography parameters. Further, a detailed cross-sectional analysis of surface and subsurface layer morphology was performed using electron microscopy including chemical composition analysis. In order to study microstructural changes in the material at the atomic level, a lamella was created, which was then studied using a transmission electron microscope.

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“…The linear and interactive effects of the cutting parameters and cutting edge angle are tabulated in Table 5 . As is expected from the popular formula [ 56 ] which is given in (4), the change in surface roughness is proportional to the square of the feed rate. The analysis result of the surface was found to be reliable as a 95% confidence interval appears.…”

Section: Resultsmentioning

confidence: 76%

Modeling of Cutting Parameters and Tool Geometry for Multi-Criteria Optimization of Surface Roughness and Vibration via Response Surface Methodology in Turning of AISI 5140 Steel

et al. 2020

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AISI 5140 is a steel alloy used for manufacturing parts of medium speed and medium load such as gears and shafts mainly used in automotive applications. Parts made from AISI 5140 steel require machining processes such as turning and milling to achieve the final part shape. Limited research has been reported on the machining vibration and surface roughness during turning of AISI 5140 in the open literature. Therefore, the main aim of this paper is to conduct a systematic study to determine the optimum cutting conditions, analysis of vibration and surface roughness under different cutting speeds, feed rates and cutting edge angles using response surface methodology (RSM). Prediction models were developed and optimum turning parameters were obtained for averaged surface roughness (Ra) and three components of vibration (axial, radial and tangential) using RSM. The results demonstrated that the feed rate was the most affecting parameter in increasing the surface roughness (69.4%) and axial vibration (65.8%) while cutting edge angle and cutting speed were dominant on radial vibration (75.5%) and tangential vibration (64.7%), respectively. In order to obtain minimum vibration for all components and surface roughness, the optimum parameters were determined as Vc = 190 m/min, f = 0.06 mm/rev, κ = 60° with high reliability (composite desirability = 90.5%). A good agreement between predicted and measured values was obtained with the developed model to predict surface roughness and vibration during turning of AISI 5140 within a 10% error range.

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Fundamentals of Metal Machining and Machine Tools

Cited by 117 publications

References 0 publications

Influence of Al content on machinability of AM series magnesium alloys

Influence of Al content on machinability of AM series magnesium alloys

Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM

Modeling of Cutting Parameters and Tool Geometry for Multi-Criteria Optimization of Surface Roughness and Vibration via Response Surface Methodology in Turning of AISI 5140 Steel

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