Influence of the Minimum Chip Thickness on the Obtained Surface Roughness During Turning Operations

Schultheiss, Fredrik; Hägglund, Sören; Bushlya, Volodymyr; Zhou, Jinming; Ståhl, Jan-Eric

doi:10.1016/j.procir.2014.04.012

Cited by 36 publications

(20 citation statements)

References 10 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…It is well known that the theoretical geometrical surface roughness is primarily a function of the feed rate for a given nose radius and varies with the square of the feed rate value. This is in good agreement with the established following equation (Davim et al, 2008;Schultheiss et al, 2014).…”

Section: Surface Roughnesssupporting

confidence: 91%

Quality-productivity decision making when turning of Inconel 718 aerospace alloy: A response surface methodology approach

Tebassi¹,

Yallese²,

Belhadi³

et al. 2017

10.5267/j.ijiec

View full text Add to dashboard Cite

Inconel 718 is among difficult to machine materials because of its abrasiveness and high strength even at high temperature. This alloy is mainly used in aircraft and aerospace industries. Therefore, it is very important to reveal and evaluate cutting tools behavior during machining of this kind of alloy. The experimental study presented in this research work has been carried out in order to elucidate surface roughness and productivity mathematical models during turning of Inconel 718 superalloy (35 HRC) with SiC Whisker ceramic tool at various cutting parameters (depth of cut, feed rate, cutting speed and radius nose). A small central composite design (SCCD) including 16 basics runs replicated three times (48 runs), was adopted and graphically evaluated using Fraction of design space (FDS) graph, completed by a statistical analysis of variance (ANOVA). Mathematical models for surface roughness and productivity were developed and normality was improved using the Box-Cox transformation. Results show that surface roughness criterion Ra was mainly influenced by cutting speed, radius nose and feed rate, and that the depth of cut had major effect on productivity. Finally, ranges of optimized cutting conditions were proposed for serial industrial production. Industrial benefit was illustrated in terms of high surface quality accompanied with high productivity. Indeed, results show that the use of optimal cutting condition had an industrial benefit to 46.9 % as an improvement in surface quality Ra and 160.54 % in productivity MRR.

show abstract

Section: Surface Roughnesssupporting

confidence: 91%

Quality-productivity decision making when turning of Inconel 718 aerospace alloy: A response surface methodology approach

Tebassi¹,

Yallese²,

Belhadi³

et al. 2017

10.5267/j.ijiec

View full text Add to dashboard Cite

show abstract

“…The reliable estimation of minimum uncut chip thickness has also the significant meaning in relation to the surface roughness prediction. According to Schultheiss et al [46], the application of the surface roughness model considering kinematic-geometric dependencies and elastic-plastic deformations of work piece (related to h min ) enables the accurate prediction of Ra and Rz roughness parameters during precision turning with low feed values. Therefore, the results obtained in this research can be further applied to the optimal selection of cutting parameters during LAM of WC/NiCr clad layers, enabling the obtainment of high surface quality.…”

Section: Resultsmentioning

confidence: 99%

The study on minimum uncut chip thickness and cutting forces during laser-assisted turning of WC/NiCr clad layers

Przestacki

Chwalczuk

Wojciechowski

2017

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Laser cladding technology enables the regeneration or manufacturing of machine parts with the improved surface layer properties. The materials applied during the laser cladding processes very often contain hard and wear-resistant tungsten carbide (WC) particles. However, the parts obtained after the laser cladding have usually unsatisfactory surface quality and thus require post-process finishing. In addition, the content of WC particles causes that clad layers are difficult to cut. Therefore, in order to improve their machinability, the laser-assisted machining (LAM) technology can be applied. Nevertheless, the material removal mechanisms during LAM of WC/NiCr clad layers are not recognized. Thus, this study is focused on the estimation of minimum uncut chip thickness and analysis of cutting forces which are important factors describing the chip decohesion process. The proposed method is based on the novel approach dedicated directly to the oblique cutting, considering the zeroth tangential force increment located onto rounded cutting edge. The experimental procedure involves cutting force component (F c , F f , F p ) measurements in the range of variable cutting conditions, as well as the cutting tool's micro-geometry inspection. On the basis of the measurements carried out, the force regression equations are formulated and subsequently applied to the determination of tangential force expression. Subsequently, the minimum uncut chip thickness is calculated on the basis of the equation derived from the zero tangential force increment condition and presented in function of cutting speed. The obtained results enable the effective selection of the cutting parameters during LAM of WC/NiCr clad layers.

show abstract

“…Through expanding the analytical equation, Eq. 1, a more accurate model could be obtained as validated through previous research [12], Eq. 2.…”

Section: Introductionmentioning

confidence: 81%

Modeling the cost of varying surface finish demands during longitudinal turning operations

Schultheiss

Hägglund²,

Ståhl

2015

Int J Adv Manuf Technol

Self Cite

View full text Add to dashboard Cite

Tolerances, including geometry, dimension, and surface roughness, are an important part of production where the desire to manufacture quality products have to be weighed against the increase of manufacturing costs. The desired tolerance will influence the choice of both manufacturing method and machine tool. Given that machining is an adequate production method, variation of the required tolerances will imply a variation of the part cost which needs to be taken into account during production planning. Thus, the term "tolerance cost" is introduced. The paper presents a model for evaluating the tolerance cost in respect to the surface roughness during longitudinal turning operations, enabling a better comparison between different production alternatives. Through knowledge of the required surface roughness, it is possible to estimate appropriate cutting conditions. Knowledge of the cutting conditions and the part geometry then makes it possible to calculate the cycle time, information which in turn may be used for calculating the corresponding part cost. Through using experimental data, it is proven that the required surface roughness has a significant influence on the attained manufacturing cost. For instance, while longitudinally turning AISI 4140, it was shown that an improvement of the surface roughness from R a =3.2 μm to R a =1.6 μm will entail an increase of the part cost by roughly 20 %. Similarly, a decrease of the required surface quality (larger R a value) will imply a significantly reduced part cost.

show abstract

Influence of the Minimum Chip Thickness on the Obtained Surface Roughness During Turning Operations

Cited by 36 publications

References 10 publications

Quality-productivity decision making when turning of Inconel 718 aerospace alloy: A response surface methodology approach

Quality-productivity decision making when turning of Inconel 718 aerospace alloy: A response surface methodology approach

The study on minimum uncut chip thickness and cutting forces during laser-assisted turning of WC/NiCr clad layers

Modeling the cost of varying surface finish demands during longitudinal turning operations

Contact Info

Product

Resources

About