Optimization of Cutting Parameters for Minimization of Cutting Temperature and Surface Roughness in Turning of Al6061 Alloy

Rajesh, N.; Yohan, M.; Venkataramaiah, P.; pallavi, M. Vani

doi:10.1016/j.matpr.2017.07.210

Cited by 15 publications

(4 citation statements)

References 7 publications

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“…Rajesh et al have done the analysis on optimization of cutting parameters for the minimization of cutting temperature and surface roughness in turning of Al 6061 alloy. 13 This study was focused on sustainable turning of AI 6061-T6 at high cutting speeds. They found that during machining, specific cutting energy reduced by 5%, and an improvement of 33% in material removal rate was achieved, while surface roughness remained unaffected.…”

Section: Introductionmentioning

confidence: 99%

Analyzing chatter vibration during turning on computer numerical control lathe using ensemble local mean decomposition and probabilistic approach

Gupta

Singh

2021

Noise & Vibration Worldwide

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Chatter vibration is an undesired and indispensable phenomenon in turning operation, which cannot be completely avoided. However, it can be suppressed by early identification and with the proper choice of input turning parameters. The key issue of chatter detection is to process the acquired signals and extract the features pertaining to it. In the present work, a methodology has been proposed for exploring tool chatter features in the incipient stage during turning on lathe. Chatter signals generated during the turning of Al 6061-T6 have been acquired using a microphone. A stability lobe diagram has been plotted to access the stability regime. Further, in order to study the effect of feed rate on stability, the recorded signals have been processed using a local mean decomposition signal processing technique, followed by the selection of dominating product functions using the Fourier transform. The decomposed signals have been used to evaluate the new output parameter, that is, chatter index. Further, the Nakagami probability distribution has been used to ascertain stability region (threshold). From the experimental validation, it has been inferred that cutting combinations obtained from the Nakagami probability distribution are significant and capable of limiting chatter vibrations. The present methodology will serve as guidelines to the researchers and machinist for the identification of tool chatter in the incipient stage, explore its severity, and finally suppress it with the proper selection of input turning parameters.

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Section: Introductionmentioning

confidence: 99%

Analyzing chatter vibration during turning on computer numerical control lathe using ensemble local mean decomposition and probabilistic approach

Gupta

Singh

2021

Noise & Vibration Worldwide

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“…Balaji et al [22] employed an orthogonal method to conduct drilling experiments and used surface roughness and amplitude as targets to evaluate the significance of tool life and cutting parameters and obtain the optimal level of cutting parameters. Rajesh [23] used high-speed steel tools to perform turning experiments on Al6061 workpiece materials under different cutting parameter values. With cutting temperature and surface roughness as the target, a regression model related to cutting temperature and surface roughness was established, and then a genetic algorithm was used.…”

Section: Introductionmentioning

confidence: 99%

Minimizing the Energy Consumption of Holes Machining Integrating the Optimization of Tool Path and Cutting Parameters on CNC Machines

Feng

Chen

Zhang

et al. 2021

Preprint

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The application of sustainable manufacturing technologies is the new challenge faced by enterprises, industries, and researchers under the background of supporting carbon peak and carbon neutral. This paper studies how to reduce the energy consumption of holes machining through optimizing tool path and cutting parameters simultaneously. The integrated optimization methodology can further reduce the energy consumption comparing with optimizing the tool path or cutting parameters separately. Firstly, the energy model of holes machining is established based on machine tools’ energy composition, tool path planning, and process parameters. Due to tool path planning as air cutting process has big relationship with reducing energy, especially for holes group with a big proportion in the whole process. The tool path of holes processing is optimized by the improved ant colony algorithm to solve the issue considering the distance from one hole to the next hole. Based on this optimized path, a multi-objective optimization model for hole cutting parameters is established, considering the spindle speed and feed rate as the optimization variables and machining time, energy consumption, and surface roughness as the objective function. The non-dominated sorting genetic algorithm (NSGA-Ⅱ) is employed to solve the multi-objective optimization problem of holes machining. The case study with 50 holes is used to testify the application of the proposed method to provide the practical energy efficiency strategy for holes group or multi-hole parts on CNC machines assisting in achieving sustainable production in manufacturing sectors.

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“…Ha [49] found the cutting temperature increase with the increasing of cutting speed on CFRP in high-speed machining, and resulted in the chips deforming from powder to spalling. Rajesh [50] established the regression equation about the influence of cutting parameters on cutting temperature and surface roughness and optimized it with a genetic algorithm to select the optimal cutting parameters. The research of the cutting temperature in drilling thermo plastic polymers by Weinert [51] showed that low cutting speed and high feeds are helpful to realize favored tool temperature and to reduce heat impact zone.…”

Section: Introductionmentioning

confidence: 99%

Machining temperature comparative analysis of end mill and novel tool in orbital drilling of CFRP composite

Kong

Gao

2021

Preprint

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Applying Carbon fiber-reinforced plastics (CFRPs) instead of traditional materials can improve the structural strength and reduce the weight of the spacecraft. However, the defects and the rejections still impede the wide application of CFRP for the contrasting thermo-mechanical properties of fibers and resin. A lower machining temperature can reduce burrs and delamination effectively. To study the cutting temperature of orbital drilling in CFRP, the processing temperature of the conventional orbital drilling (COD) was compared with the novel orbital drilling and reaming tool (ODR), and a heat transfer model considering the influence of convective heat transfer on cutting temperature was also proposed in this research, which can explain the reason of the novel tool with a lower cutting temperature. On the basis of the analysis of the kinematic mechanisms, a cutting force prediction model for the process of orbital drilling was presented. The three-dimensional, unsteady state, nonhomogeneous partial differential heat transfer equation in polar coordinates was established, and solved with the finite difference approach. The results show that the predictions of models are coincided to the experimental data, and ODR tool can reduce the processing temperature of orbital drilling effectively.

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Optimization of Cutting Parameters for Minimization of Cutting Temperature and Surface Roughness in Turning of Al6061 Alloy

Cited by 15 publications

References 7 publications

Analyzing chatter vibration during turning on computer numerical control lathe using ensemble local mean decomposition and probabilistic approach

Analyzing chatter vibration during turning on computer numerical control lathe using ensemble local mean decomposition and probabilistic approach

Minimizing the Energy Consumption of Holes Machining Integrating the Optimization of Tool Path and Cutting Parameters on CNC Machines

Machining temperature comparative analysis of end mill and novel tool in orbital drilling of CFRP composite

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