Investigation of surface roughness in face milling processes

Increasing demand for aluminum matrix composites (AMCs) in the manufacturing sector leads to the development of squeeze casted hybrid AMCs bearing superior mechanical attributes. Excessive hardness due to squeeze pressure and the presence of reinforcement particles makes the machining of AMCs challenging and results in excessive tool wear and inadequate surface finish. Wire electric discharge machining (WEDM) process has been preferred over conventional manufacturing processes for the machining of squeeze casted Al2024/Al2O3/W hybrid composite. This study investigates the selection of the most pertinent wire electrode for the precise machining of Al2024/Al2O3/W. Simple zinc-coated (NT) and cryogenic treated (CT) brass wire electrodes have been selected for machining. Scanning electron microscope (SEM) analysis of CT wire shows that cryogenic treatment enhances the soundness and stability by reducing microcavities in its microstructure. To analyze the effects of cryogenic treatment, the machining performance of CT wire has been compared with NT wire. Besides wire type, the influence of key input variables has also been analyzed on the imperative response measures including cutting speed (CS), surface roughness (SR) and kerf width (KW) to make the machining process more effective. Microstructural analysis of NT wire depicts a high concentration of micro-voids, micro-cracks, and deep craters, while the surface of CT has been observed relatively fine after the machining. Comparative analysis of both wire electrodes has declared that CT wire yields 26.96% and 15.10% superior results for CS and SR respectively, and 6.92% deprived results for KW than NT wire.

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“…In previous studies, numerous statistical techniques including Factorial design [41], Taguchi method [42],…”

Section: Experimental Design 241 Response Surface Methodologymentioning

confidence: 99%

Cryogenic Treatment Analysis in WEDM of Al2024/Al2O3/W Composite

Raza

Ali

Tahir

et al. 2021

Preprint

Self Cite

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“…Utilizing the S/N ratio and contour plots, single-response optimization is carried out. The development of empirical Ra and MRR models for all cutting situations is done, and the effectiveness of these models is assessed using analysis of variance (ANOVA) [2]. In this study, Bizhan Rahmati et al created a nanolubricant comprising MoS2 nanoparticles for end milling of AL6061-T6 alloy and also looked into the surface morphology of the machined workpiece [3].…”

Section: Literature Referencementioning

confidence: 99%

Experimental Investigation on Al 6061 and Al 2024 Aluminium Alloys for Achieving Surface Roughness Using CNC Vertical Face Milling Process

Poornesh

Sunith

Hemavathy

2022

KEM

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The influence of process factors and the integrity of the surface roughness are investigated experimentally in the current study on the metals Al6061 and Al2024. In order to conduct vertical cutting tests for both base alloys, a mixed-level L9 orthogonal array is used. An optical emission spectrometer is used to analyze the chemical composition. SEM is used to analyse the microstructure of the materials used to discover tiny inertinitic precipitates in an aluminum matrix using ANOVA Table value. Mild steel was the tool employed, and surface topography and 2D roughness profile data were used to assess the surface integrity of cut surfaces. The experimental trials with various degrees of process parameters, such as Taguchi L9 orthogonal array. In determining surface roughness, speed, feed, and depth of cut are determined to be the most important variables.

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“…An increase in cutting force has resulted in an increase in surface roughness. A coolant-based analysis of machining to achieve better surface quality is one of the methods studied by Raza et al [4]. Tool wear and tool vibration may be included in the prediction models to improve accuracy, as in Saini et al's [5] work.…”

Section: Introductionmentioning

confidence: 99%

An Experimental Study on Nodular Iron Machined Surfaces Utilizing a Capable 2D Finite Element Model for Precise Surface Roughness Estimation

Teke,

Ertas

2024

Processes

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Nodular iron plays a crucial role in various industries, especially in large-scale applications such as gearboxes. Ensuring that nodular iron remains free from oil leakage and that contact surfaces are properly aligned is essential, given its operational requirements. Achieving flat contact faces through precise machining is therefore of utmost importance. As surface roughness and flatness are closely linked, it is vital to investigate the machining process parameters involved. This study focuses on addressing surface quality issues with EN-GJS-600-3 cast iron by optimizing machining parameters. CMM measurements were utilized to analyze the relationship between surface roughness and flatness, with a surface profile used to assess flatness. Furthermore, a new 2D surface roughness estimation method (2D-SRET) was created and tested with experimental data in order to improve the precision of assessing the discrete flat surface machining procedure.

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Investigation of surface roughness in face milling processes

Cited by 19 publications

References 48 publications

Cryogenic Treatment Analysis in WEDM of Al2024/Al2O3/W Composite

Cryogenic Treatment Analysis in WEDM of Al2024/Al2O3/W Composite

Experimental Investigation on Al 6061 and Al 2024 Aluminium Alloys for Achieving Surface Roughness Using CNC Vertical Face Milling Process

An Experimental Study on Nodular Iron Machined Surfaces Utilizing a Capable 2D Finite Element Model for Precise Surface Roughness Estimation

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