This paper investigated the feasibility of drilling aluminum 7050 with enhanced cutting speed. Two identical tools and two identical Al-7050 work-piece plates were utilised during the experiment. Wet
cooling drilling on both conventional and high cutting speeds was conducted to compare the results. A total of 338 holes were drilled towards the end of the experiment. Tests for tool wear, borehole diameter, and hole quality were carried out to observe the different drilling performances by drilling with different cutting speeds. The result shows that the proposed high speed drilling produced better diameter accuracy,better surface roughness but poor exit burr hole tendency.
This document summarizes an investigation into flank wear on minimal cutting fluid application during turning of OHNS steel. Seven input parameters were varied at three levels in a 27-run Taguchi experiment. Analysis found that feed rate had the greatest influence on flank wear, cutting temperature, and chip thickness based on ANOVA. Optimal cutting and fluid application parameters were determined to be a cutting speed of 168.23 m/min, feed of 0.04 mm/rev, depth of cut of 1 mm, pressure of 100 bar, frequency of 900 pulses/min, application rate of 3 ml/min, and fluid composition of 20%. The study provides optimized parameters for improved tool performance during turning of OHNS steel with minimal cutting fluid application.
The document discusses a master's project investigating the influence of drilling parameters on burr formation and size for low carbon steel and stainless steel. It outlines the drilling process and issues caused by burrs. The project will experimentally test different drilling speeds, feed rates, drill diameters, workpiece materials and thicknesses. It describes the methodology, including material selection and specifications, equipment used, parameter selection, measurement of burr heights, and how results will be analyzed in stages to understand effects on burr formation. The goal is to identify optimal drilling conditions to minimize burrs.
Statistical Modeling of Surface Roughness produced by Wet turning using solub...IDES Editor
Machining tests were carried out by turning En-
31steel alloy with tungsten carbide tools using soluble oilwater
mixture lubricant under dif ferent machining
conditions. First-order and second-order surface roughness
predicting models were developed by using the experimental
data by applying response surface methodology and factorial
design of experiments. The established equations show that
the feed rate is the main influencing factor on the surface
roughness followed by tool nose radius and depth of cut. It
increases with increase in the feed rate but decreases with
increase in the cutting velocity and tool nose radius,
respectively. The predicted surface roughness values of the
samples have been f ound to lie close to that of the
experimentally observed values. There is an improvement
in surface finish by 10% with wet machining as compared
to dry machining.
API 570 covers inspection, repair, alteration and re-rating procedures for metallic piping systems that have been in-service. It was developed for the petroleum refining and chemical process industries and applies to piping systems for flammable and toxic fluids. The document contains 53 practice questions related to API 570 covering topics like corrosion mechanisms, inspection techniques, qualifications of inspectors and more. Respondents are asked to pick the correct option from the given choices for each question.
Effects of Cutting Tool Parameters on Surface Roughnessirjes
This paper presents of the influence on surface roughness of Co28Cr6Mo medical alloy machined
on a CNC lathe based on cutting parameters (rotational speed, feed rate, depth of cut and nose radius).The
influences of cutting parameters have been presented in graphical form for understanding. To achieve the
minimum surface roughness, the optimum values obtained for rpm, feed rate, depth of cut and nose radius were
respectively, 318 rpm, 0,1 mm/rev, 0,7 mm and 0,8 mm. Maximum surface roughness has been revealed the
values obtained for rpm, feed rate, depth of cut and nose radius were respectively, 318 rpm, 0,25 mm/rev, 0,9
mm and 0,4 mm.
Optimization of turning process parameter in dry turning of sae52100 steelIAEME Publication
This document discusses optimizing surface roughness and material removal rate in dry turning of SAE52100 steel. Experiments were conducted using different cutting speeds, feeds, and depths of cut. Surface roughness and material removal rate were measured for each experimental condition. The results were analyzed using Taguchi methods to determine the optimal levels for each process parameter to minimize surface roughness and maximize material removal rate. The analysis found that feed rate had the greatest influence on surface roughness, while cutting speed had the greatest influence on material removal rate.
The document describes an experimental investigation of polycrystalline cubic boron nitride (PCBN) cutting tool inserts when hard turning hardened 42CrMo4 steel. Individual cutting parameters were evaluated to quantitatively assess their influence on general tool wear patterns. The results indicated that PCBN tool inserts demonstrated good wear resistance regardless of the hardness of the 42CrMo4 steel at 62HRC. Tool life decreased with increasing cutting speed and feed rate based on a permissible flank wear criterion of 0.3mm. Surface roughness also generally increased with greater tool wear.
This document contains a practice exam for API 510 certification. It includes 26 multiple choice questions covering topics like corrosion rates, inspection responsibilities, weld procedures, and non-destructive testing. The answers are provided at the end with references to API and ASME codes. This exam tests an individual's knowledge of pressure vessel inspection, alteration, and repair standards and qualifications.
This document summarizes an investigation into flank wear on minimal cutting fluid application during turning of OHNS steel. Seven input parameters were varied at three levels in a 27-run Taguchi experiment. Analysis found that feed rate had the greatest influence on flank wear, cutting temperature, and chip thickness based on ANOVA. Optimal cutting and fluid application parameters were determined to be a cutting speed of 168.23 m/min, feed of 0.04 mm/rev, depth of cut of 1 mm, pressure of 100 bar, frequency of 900 pulses/min, application rate of 3 ml/min, and fluid composition of 20%. The study provides optimized parameters for improved tool performance during turning of OHNS steel with minimal cutting fluid application.
The document discusses a master's project investigating the influence of drilling parameters on burr formation and size for low carbon steel and stainless steel. It outlines the drilling process and issues caused by burrs. The project will experimentally test different drilling speeds, feed rates, drill diameters, workpiece materials and thicknesses. It describes the methodology, including material selection and specifications, equipment used, parameter selection, measurement of burr heights, and how results will be analyzed in stages to understand effects on burr formation. The goal is to identify optimal drilling conditions to minimize burrs.
Statistical Modeling of Surface Roughness produced by Wet turning using solub...IDES Editor
Machining tests were carried out by turning En-
31steel alloy with tungsten carbide tools using soluble oilwater
mixture lubricant under dif ferent machining
conditions. First-order and second-order surface roughness
predicting models were developed by using the experimental
data by applying response surface methodology and factorial
design of experiments. The established equations show that
the feed rate is the main influencing factor on the surface
roughness followed by tool nose radius and depth of cut. It
increases with increase in the feed rate but decreases with
increase in the cutting velocity and tool nose radius,
respectively. The predicted surface roughness values of the
samples have been f ound to lie close to that of the
experimentally observed values. There is an improvement
in surface finish by 10% with wet machining as compared
to dry machining.
API 570 covers inspection, repair, alteration and re-rating procedures for metallic piping systems that have been in-service. It was developed for the petroleum refining and chemical process industries and applies to piping systems for flammable and toxic fluids. The document contains 53 practice questions related to API 570 covering topics like corrosion mechanisms, inspection techniques, qualifications of inspectors and more. Respondents are asked to pick the correct option from the given choices for each question.
Effects of Cutting Tool Parameters on Surface Roughnessirjes
This paper presents of the influence on surface roughness of Co28Cr6Mo medical alloy machined
on a CNC lathe based on cutting parameters (rotational speed, feed rate, depth of cut and nose radius).The
influences of cutting parameters have been presented in graphical form for understanding. To achieve the
minimum surface roughness, the optimum values obtained for rpm, feed rate, depth of cut and nose radius were
respectively, 318 rpm, 0,1 mm/rev, 0,7 mm and 0,8 mm. Maximum surface roughness has been revealed the
values obtained for rpm, feed rate, depth of cut and nose radius were respectively, 318 rpm, 0,25 mm/rev, 0,9
mm and 0,4 mm.
Optimization of turning process parameter in dry turning of sae52100 steelIAEME Publication
This document discusses optimizing surface roughness and material removal rate in dry turning of SAE52100 steel. Experiments were conducted using different cutting speeds, feeds, and depths of cut. Surface roughness and material removal rate were measured for each experimental condition. The results were analyzed using Taguchi methods to determine the optimal levels for each process parameter to minimize surface roughness and maximize material removal rate. The analysis found that feed rate had the greatest influence on surface roughness, while cutting speed had the greatest influence on material removal rate.
The document describes an experimental investigation of polycrystalline cubic boron nitride (PCBN) cutting tool inserts when hard turning hardened 42CrMo4 steel. Individual cutting parameters were evaluated to quantitatively assess their influence on general tool wear patterns. The results indicated that PCBN tool inserts demonstrated good wear resistance regardless of the hardness of the 42CrMo4 steel at 62HRC. Tool life decreased with increasing cutting speed and feed rate based on a permissible flank wear criterion of 0.3mm. Surface roughness also generally increased with greater tool wear.
This document contains a practice exam for API 510 certification. It includes 26 multiple choice questions covering topics like corrosion rates, inspection responsibilities, weld procedures, and non-destructive testing. The answers are provided at the end with references to API and ASME codes. This exam tests an individual's knowledge of pressure vessel inspection, alteration, and repair standards and qualifications.
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This document summarizes an experiment to optimize surface roughness and material removal rate during dry turning of SAE52100 steel. The experiment varied cutting speed, feed rate, and depth of cut using a Taguchi L9 orthogonal array. Surface roughness increased with increasing feed rate and decreasing cutting speed. Material removal rate models were developed that showed it increases with cutting speed and depth of cut but decreases with feed rate. Analysis found feed rate has the greatest influence on surface roughness, while depth of cut most influences material removal rate. The goal of the experiment was to determine optimal machining parameters that minimize surface roughness and maximize material removal rate and productivity during dry turning of SAE52100 steel.
Tool wear and inclusion behaviour during turning of a calcium treated quenc...Lepuufu
1. The document analyzes tool wear and inclusion behavior during turning of a calcium-treated steel using coated carbide tools.
2. It finds that inclusions like MnS, mixed sulphides (Mn,Ca)S, and duplex calcium aluminates deform significantly in the flow zone near the tool. MnS deforms the most while mixed sulphides deform less.
3. The behavior and deformation of inclusions in the flow zone influences tool wear and formation of protective layers on the tool surface. Certain inclusions like mixed sulphides are more likely to form protective layers due to their deformation characteristics.
A literature review on optimization of cutting parameters for surface roughne...IJERD Editor
This document summarizes literature on optimizing cutting parameters to improve surface roughness in turning processes. Several studies used Taguchi methods to optimize parameters like cutting speed, feed rate, depth of cut, and nose radius. Most found feed rate was the most influential parameter on surface roughness. Other key findings include that lower feed rates and depths of cut produce better surface finishes, and coatings on carbide inserts can improve tool performance and surface roughness when machining steels. Future work could optimize additional parameters and study different tool coatings.
Extrusion can be defined as the process of subjecting a material to compression so that it is forced to
flow through an opening of a die and takes the shape of the hole. Multi-hole extrusion is the process of
extruding the products through a die having more than one hole. Multi-hole extrusion increases the production
rate and reduces the cost of production. In this study the ram force has calculated experimentally for single hole
and multi-hole extrusion. The comparison of ram forces between the single hole and multi-hole extrusion
provides the inverse relation between the numbers of holes in a die and ram force. The experimental lengths of
the extruded products through the various holes of multi-hole die are different. It indicates that the flow pattern
is dependent on the material behavior. The micro-hardness test has done for the extruded products of lead
through multi-hole die. It is observed that the hardness of the extruded lead products from the central hole is
found to be more than that of the products extruded from other holes. The study suggests that multi-hole
extrusion can be used for obtaining the extruded products of lead with varying hardness. The micro-structure
study has done for the lead material before and after extrusion. It is observed that the size of grains of lead
material after extrusion is smaller than the original lead.
Fatigue Performance in Grinding and Turning: An OverviewIJMER
This paper analysis the influence of Abrasive Flow Machining (AFM), Turning and Grinding on
fatigue performance of Fe250. Surface condition has a strong effect on fatigue life, and that most surfaces
produced by conventional manufacturing operations such as machining and forging have poor fatigue
behavior than polished surfaces commonly used for laboratory specimens. It is found that the surfaces
produced with different machining process and having the same surface roughness having different fatigue
performances. High –cycle fatigue data was obtained for Fe 250 using three types of machining process
viz, AFM, Turning and Grinding .S-N curve is plotted for the samples obtained with all the three process. It
was found that the samples produced with AFM having the highest fatigue life.
Image segmentation, Rough set Theory, Game Theory, Image processingijsrd.com
Valve is most common part for every Fluid handling industry. Production of cast Valve is critical because, in today's competitive world customer wants fast and accurate Component. Computer simulation tools are used to reduce a time for development of a component. Simulation software is mainly used to visualize a complete process of solidification, which is not possible in real casting process. Defects such as shrinkage porosity, gas porosity, unfilled mould, cold shut etc. can also graphically observe with simulation. Initially CAD model of impeller has been prepared, then export for simulation. Many researchers reported that about 90% of the defects in castings are due to wrong design of gating system and only 10% due to manufacturing problems. Casting simulation process can able to solve these problems. To study the solidification behavior and detection of hot spots in castings with the help of casting simulation software. The simulated results also compared with the experimental works.
Charge Weld Prediction and Minimization in Extrusion - Choose ahead, choose A...Tommaso Pinter
Today with FE simulation we can help extrusion companies to predict and reduce front scrap thus allowing them to precisely estimate the production cost of a drawing profile before the contract is signed and the die is ordered.
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
Extrusion process and parameters involved in the experimental and numerical i...IJERD Editor
This document reviews extrusion processes and parameters for investigating aluminum alloys Al6061, Al6063, and Al7075. It discusses experimental and numerical methods used to study the effects of parameters like die angle, billet temperature, speed, and geometry. Taguchi methods were used to optimize parameters for Al6061 extrusion. Numerical analysis found the maximum stresses occur at square tube corners. The document concludes that smaller extrusion ratios and stresses result from thicker products and fixed billet dimensions. Parameters like die angle, temperature, speed, and geometry influence load, strength, and deformation during aluminum extrusion.
Cryogenic treatment is a secondary process to traditional heat treatment used for improving the hardness and wear resistance of tool steels. Though the potential use of cryogenic treatment on AISI D2 tool steel under laboratory conditions has been well established by the researchers, it is essential to do the analysis to ensure its sustainable use for industrial application. Therefore, impact of cryogenic treatment on AISI D2 steel blanking punch was evaluated in terms of increase in production rate and its life. The cryogenically treated D2 tool steel punches were used and subjected to manufacture the control levers using blanking operations. The improved wear resistance of cryogenically treated punch resulted in increase in production and punch life more than 200%. Punch life was studied and correlated to increase in production & wear behavior of blanking punch. The AISI D2 steel samples were prepared and subjected to laboratory tests comprising of metallographic observations and hardness. It was found that laboratory tests were not enough to predict improvements in mechanical properties. The mechanism responsible for augmented wear resistance by cryogenic treatment was the conversion of retained austenite to martensite and precipitation of new secondary carbides.
Literature review of increasing tool life of hot forging die by reducing wear Bhavesh Panchal
By various coating and deposition method tool life increases of hot forging die. There are 5 research paper from trusted and authorised sites. Review of that papers have been shown here.
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
Comparison of Mechanical Properties of Austempered, Normalized and As-Weld Ca...IJAEMSJORNAL
More often than not, welded joints experience failure such as fracture which jeopardize their reliability and ergonomics when put in perspective. Attempting a significant improvement in the mechanical properties of welded joint through heat treatment could ensure joints stability and reduce the costs associated with constant repairs and replacements. In this study, the effects of heat treatments (austempering and normalization) on the mechanical properties of weldments were examined. The locally recycled steel sample was sourced from the Delta Steel Company Aladja, Delta State and the spectro-analysis was carried out on it. The test samples were machined as per properties for tests, fractured locally and were welded using shielded metal arc welding (SMAW) with stainless steel electrode. They were then heat treated in electric furnaces. The mechanical properties (tensile strength, yield strength, hardness and impact toughness) were determined and the microstructure examined using scanning electron microscope. They were also examined physically using hand lens. The result indicated that the austempered samples improved significantly in terms of its tensile strength, yield strength, hardness and ductility. It was also found that the untreated sample produced the greatest impact toughness. The result of the physical examination also suggested that heat treatment using oil based quenchant have the potential to inhibit rust at weld joints.
This document summarizes a study that optimized cutting parameters and the grinding process for surface roughness using the Taguchi method and computational fluid dynamics (CFD) analysis. The study aimed to achieve a good surface finish by optimizing parameters like cutting fluid, wheel speed, workpiece speed, depth of cut, grinding wheel grades, and material hardness. CFD analysis was used to simulate the grinding process and analyze temperature, pressure, velocity, and coolant flow distributions. The Taguchi method was employed to investigate the effects of parameters on surface roughness and find the optimum parameters. The results showed that coolant flow rate and table speed had significant effects on surface roughness, while depth of cut had a lower effect.
The Influence of Shot Angle Variation at the Process of Dry Shot Peening to t...IJAEMSJORNAL
AISI 316L is the austenitic stainless steel type that widely used in biomedical implant and artificial organs. This material’s cannot be hardened by heat treatment but the mechanical strength could be increased by cold working process. Dry shot peening is the one of cold working process in which the surface specimen bombarded with spherical media called shot to produce a compressive residual stress layer and modify mechanical properties of metal’s surface. The objectives of this research are to investigate the effect of shot angle variation of dry shot peening process on the surface roughness and corrosion resistance of AISI 316L.
Experimental Analysis using Established Parameters for Cryogenic Treatment on...IJAEMSJORNAL
The experimental analysis on cutting tool material is done with referring the established parameters for Cryogenic Treatment. The pilot experimentation is carried out using the Conventional heat treated tool bits as supplied condition and Cryogenic treated tools. The three grades of high speed steel are identified for the investigation purpose and for pilot experimentation H.S.S. T42 grade is selected. The tool material procured is strictly as per the grade specifications for the investigation of effect of cryogenic treatment on tool life. The established parameters for cryogenic treatment are identified referring to previous published research and machining parameters as per the industry specifications. The pilot experimentation using Untreated and treated tools are subjected to turning operation on CNC turning center for a definite work material and machining parameters such as cutting speed, feed and depth of cut are identified. Single point cutting Tool geometry is maintained as per the tool signature and length of the tool is maintained as per the limitations of the machine. The Surface Roughness of the machined work piece is measured using the Taylor Hob-son Surface Roughness tester and the Tool wear is measured using the Tool Makers microscope. The results are tabulated. An experimental effort to understand the effect of Untreated and Cryogenic treated tool on the tool life is the outcome of this paper. The outcome of this paper forms the basis of experimentation using the Orthogonal array for all the selected grades of the material.
The document describes an experiment to optimize cutting parameters during CNC turning of AISI 8620 alloy steel using response surface methodology. Speed, feed rate, and depth of cut were varied as factors in a 3-level factorial design. The response variable was surface roughness, which was measured after each experimental run. Regression analysis in Minitab was used to develop a model relating the factors to surface roughness. Response optimization was then used to determine the optimal settings of the factors to minimize surface roughness. The goal of the experiment was to evaluate the best cutting parameter settings for achieving a smooth surface finish during CNC turning of AISI 8620 alloy steel.
IRJET- Investigation on Various Aspects of using Activated Tio2 Flux in G...IRJET Journal
1) The document investigates the use of activated TiO2 flux in gas tungsten arc welding (GTAW) of stainless steel AISI 304L to improve weld penetration and hardness.
2) Experiments were conducted using Taguchi's design of experiments to evaluate the effects of welding current, speed, and flux amount on penetration and hardness.
3) Results showed that using TiO2 flux increased penetration compared to GTAW without flux. Hardness was also slightly lower when using flux, indicating less brittleness.
This document summarizes an experimental study that optimized machining parameters for cryogenic turning of AISI 4340 steel to minimize surface roughness. The researchers used Taguchi's design of experiments methodology to test cutting speed, feed rate, depth of cut, and rake angle parameters. Analysis showed cutting speed and depth of cut most influenced surface roughness. Validation experiments confirmed the optimal parameters achieved the predicted minimum surface roughness, demonstrating cryogenic machining's ability to improve surface finish.
This document summarizes a study that used Taguchi experimental design to optimize the chemical machining parameters for cold worked stainless steel 420. The study examined the effects of machining temperature, machining time, and degree of previous cold working on the surface finish. Samples with 0%, 20%, 40%, and 60% cold working were chemically machined at temperatures of 45°C, 50°C, 55°C, and 58°C for times of 2, 4, 6, and 8 minutes. Analysis of variance and regression modeling found that the degree of previous cold working was the most significant parameter affecting surface finish. The optimal conditions were determined to be 60% cold working at 45°C for 2 minutes.
Through-Hole Exit Characteristics in Drilling Of TI6AL4V and Quality Improvem...ijmech
The removal of macro-burrs formed after drilling has always been a difficult engineering problem, especially on different-machined materials with through holes. This paper aims at presenting an investigation into hole exit characteristics of Ti6Al4V drilled. Plastic deformation at the end of the cutting process or blanking results into the forming of burr, whose degree of impact is mostly affected by the processing parameters, especially the axial feed. Series experiments were conducted to analysis the effect of processing parameter on formed burr. The volume of burr has great effect on work-piece quality and product cost, the burr height formed easily decreases because great attention from scholars and engineers has been paid to, while the burr width size despised naturally plays a great influence on product quality and machining cost. The new de-burring tool are designed and applied in experiment, the decrease in burr width is obviously found, so the removal of burrs becomes much little than that gotten in traditional tool. The resulting indicates a promising future of de-burring in practical application Journals.
The document provides a review of form drilling (also known as thermal drilling), which is a non-traditional hole making process that uses heat generated from friction between a rotating conical tool and workpiece to soften the material and form a bushing. The review discusses the basics of form drilling, technical features, applications to different materials like cast metals, the working principle involving 5 steps, and prior research studying the effects of parameters like spindle speed, feed rate, tool geometry, and workpiece material on outputs like temperature, forces, surface roughness, and bushing geometry. Key findings from previous studies investigating these relationships in materials like aluminum alloys and steel are summarized.
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This document summarizes an experiment to optimize surface roughness and material removal rate during dry turning of SAE52100 steel. The experiment varied cutting speed, feed rate, and depth of cut using a Taguchi L9 orthogonal array. Surface roughness increased with increasing feed rate and decreasing cutting speed. Material removal rate models were developed that showed it increases with cutting speed and depth of cut but decreases with feed rate. Analysis found feed rate has the greatest influence on surface roughness, while depth of cut most influences material removal rate. The goal of the experiment was to determine optimal machining parameters that minimize surface roughness and maximize material removal rate and productivity during dry turning of SAE52100 steel.
Tool wear and inclusion behaviour during turning of a calcium treated quenc...Lepuufu
1. The document analyzes tool wear and inclusion behavior during turning of a calcium-treated steel using coated carbide tools.
2. It finds that inclusions like MnS, mixed sulphides (Mn,Ca)S, and duplex calcium aluminates deform significantly in the flow zone near the tool. MnS deforms the most while mixed sulphides deform less.
3. The behavior and deformation of inclusions in the flow zone influences tool wear and formation of protective layers on the tool surface. Certain inclusions like mixed sulphides are more likely to form protective layers due to their deformation characteristics.
A literature review on optimization of cutting parameters for surface roughne...IJERD Editor
This document summarizes literature on optimizing cutting parameters to improve surface roughness in turning processes. Several studies used Taguchi methods to optimize parameters like cutting speed, feed rate, depth of cut, and nose radius. Most found feed rate was the most influential parameter on surface roughness. Other key findings include that lower feed rates and depths of cut produce better surface finishes, and coatings on carbide inserts can improve tool performance and surface roughness when machining steels. Future work could optimize additional parameters and study different tool coatings.
Extrusion can be defined as the process of subjecting a material to compression so that it is forced to
flow through an opening of a die and takes the shape of the hole. Multi-hole extrusion is the process of
extruding the products through a die having more than one hole. Multi-hole extrusion increases the production
rate and reduces the cost of production. In this study the ram force has calculated experimentally for single hole
and multi-hole extrusion. The comparison of ram forces between the single hole and multi-hole extrusion
provides the inverse relation between the numbers of holes in a die and ram force. The experimental lengths of
the extruded products through the various holes of multi-hole die are different. It indicates that the flow pattern
is dependent on the material behavior. The micro-hardness test has done for the extruded products of lead
through multi-hole die. It is observed that the hardness of the extruded lead products from the central hole is
found to be more than that of the products extruded from other holes. The study suggests that multi-hole
extrusion can be used for obtaining the extruded products of lead with varying hardness. The micro-structure
study has done for the lead material before and after extrusion. It is observed that the size of grains of lead
material after extrusion is smaller than the original lead.
Fatigue Performance in Grinding and Turning: An OverviewIJMER
This paper analysis the influence of Abrasive Flow Machining (AFM), Turning and Grinding on
fatigue performance of Fe250. Surface condition has a strong effect on fatigue life, and that most surfaces
produced by conventional manufacturing operations such as machining and forging have poor fatigue
behavior than polished surfaces commonly used for laboratory specimens. It is found that the surfaces
produced with different machining process and having the same surface roughness having different fatigue
performances. High –cycle fatigue data was obtained for Fe 250 using three types of machining process
viz, AFM, Turning and Grinding .S-N curve is plotted for the samples obtained with all the three process. It
was found that the samples produced with AFM having the highest fatigue life.
Image segmentation, Rough set Theory, Game Theory, Image processingijsrd.com
Valve is most common part for every Fluid handling industry. Production of cast Valve is critical because, in today's competitive world customer wants fast and accurate Component. Computer simulation tools are used to reduce a time for development of a component. Simulation software is mainly used to visualize a complete process of solidification, which is not possible in real casting process. Defects such as shrinkage porosity, gas porosity, unfilled mould, cold shut etc. can also graphically observe with simulation. Initially CAD model of impeller has been prepared, then export for simulation. Many researchers reported that about 90% of the defects in castings are due to wrong design of gating system and only 10% due to manufacturing problems. Casting simulation process can able to solve these problems. To study the solidification behavior and detection of hot spots in castings with the help of casting simulation software. The simulated results also compared with the experimental works.
Charge Weld Prediction and Minimization in Extrusion - Choose ahead, choose A...Tommaso Pinter
Today with FE simulation we can help extrusion companies to predict and reduce front scrap thus allowing them to precisely estimate the production cost of a drawing profile before the contract is signed and the die is ordered.
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
Extrusion process and parameters involved in the experimental and numerical i...IJERD Editor
This document reviews extrusion processes and parameters for investigating aluminum alloys Al6061, Al6063, and Al7075. It discusses experimental and numerical methods used to study the effects of parameters like die angle, billet temperature, speed, and geometry. Taguchi methods were used to optimize parameters for Al6061 extrusion. Numerical analysis found the maximum stresses occur at square tube corners. The document concludes that smaller extrusion ratios and stresses result from thicker products and fixed billet dimensions. Parameters like die angle, temperature, speed, and geometry influence load, strength, and deformation during aluminum extrusion.
Cryogenic treatment is a secondary process to traditional heat treatment used for improving the hardness and wear resistance of tool steels. Though the potential use of cryogenic treatment on AISI D2 tool steel under laboratory conditions has been well established by the researchers, it is essential to do the analysis to ensure its sustainable use for industrial application. Therefore, impact of cryogenic treatment on AISI D2 steel blanking punch was evaluated in terms of increase in production rate and its life. The cryogenically treated D2 tool steel punches were used and subjected to manufacture the control levers using blanking operations. The improved wear resistance of cryogenically treated punch resulted in increase in production and punch life more than 200%. Punch life was studied and correlated to increase in production & wear behavior of blanking punch. The AISI D2 steel samples were prepared and subjected to laboratory tests comprising of metallographic observations and hardness. It was found that laboratory tests were not enough to predict improvements in mechanical properties. The mechanism responsible for augmented wear resistance by cryogenic treatment was the conversion of retained austenite to martensite and precipitation of new secondary carbides.
Literature review of increasing tool life of hot forging die by reducing wear Bhavesh Panchal
By various coating and deposition method tool life increases of hot forging die. There are 5 research paper from trusted and authorised sites. Review of that papers have been shown here.
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
Comparison of Mechanical Properties of Austempered, Normalized and As-Weld Ca...IJAEMSJORNAL
More often than not, welded joints experience failure such as fracture which jeopardize their reliability and ergonomics when put in perspective. Attempting a significant improvement in the mechanical properties of welded joint through heat treatment could ensure joints stability and reduce the costs associated with constant repairs and replacements. In this study, the effects of heat treatments (austempering and normalization) on the mechanical properties of weldments were examined. The locally recycled steel sample was sourced from the Delta Steel Company Aladja, Delta State and the spectro-analysis was carried out on it. The test samples were machined as per properties for tests, fractured locally and were welded using shielded metal arc welding (SMAW) with stainless steel electrode. They were then heat treated in electric furnaces. The mechanical properties (tensile strength, yield strength, hardness and impact toughness) were determined and the microstructure examined using scanning electron microscope. They were also examined physically using hand lens. The result indicated that the austempered samples improved significantly in terms of its tensile strength, yield strength, hardness and ductility. It was also found that the untreated sample produced the greatest impact toughness. The result of the physical examination also suggested that heat treatment using oil based quenchant have the potential to inhibit rust at weld joints.
This document summarizes a study that optimized cutting parameters and the grinding process for surface roughness using the Taguchi method and computational fluid dynamics (CFD) analysis. The study aimed to achieve a good surface finish by optimizing parameters like cutting fluid, wheel speed, workpiece speed, depth of cut, grinding wheel grades, and material hardness. CFD analysis was used to simulate the grinding process and analyze temperature, pressure, velocity, and coolant flow distributions. The Taguchi method was employed to investigate the effects of parameters on surface roughness and find the optimum parameters. The results showed that coolant flow rate and table speed had significant effects on surface roughness, while depth of cut had a lower effect.
The Influence of Shot Angle Variation at the Process of Dry Shot Peening to t...IJAEMSJORNAL
AISI 316L is the austenitic stainless steel type that widely used in biomedical implant and artificial organs. This material’s cannot be hardened by heat treatment but the mechanical strength could be increased by cold working process. Dry shot peening is the one of cold working process in which the surface specimen bombarded with spherical media called shot to produce a compressive residual stress layer and modify mechanical properties of metal’s surface. The objectives of this research are to investigate the effect of shot angle variation of dry shot peening process on the surface roughness and corrosion resistance of AISI 316L.
Experimental Analysis using Established Parameters for Cryogenic Treatment on...IJAEMSJORNAL
The experimental analysis on cutting tool material is done with referring the established parameters for Cryogenic Treatment. The pilot experimentation is carried out using the Conventional heat treated tool bits as supplied condition and Cryogenic treated tools. The three grades of high speed steel are identified for the investigation purpose and for pilot experimentation H.S.S. T42 grade is selected. The tool material procured is strictly as per the grade specifications for the investigation of effect of cryogenic treatment on tool life. The established parameters for cryogenic treatment are identified referring to previous published research and machining parameters as per the industry specifications. The pilot experimentation using Untreated and treated tools are subjected to turning operation on CNC turning center for a definite work material and machining parameters such as cutting speed, feed and depth of cut are identified. Single point cutting Tool geometry is maintained as per the tool signature and length of the tool is maintained as per the limitations of the machine. The Surface Roughness of the machined work piece is measured using the Taylor Hob-son Surface Roughness tester and the Tool wear is measured using the Tool Makers microscope. The results are tabulated. An experimental effort to understand the effect of Untreated and Cryogenic treated tool on the tool life is the outcome of this paper. The outcome of this paper forms the basis of experimentation using the Orthogonal array for all the selected grades of the material.
The document describes an experiment to optimize cutting parameters during CNC turning of AISI 8620 alloy steel using response surface methodology. Speed, feed rate, and depth of cut were varied as factors in a 3-level factorial design. The response variable was surface roughness, which was measured after each experimental run. Regression analysis in Minitab was used to develop a model relating the factors to surface roughness. Response optimization was then used to determine the optimal settings of the factors to minimize surface roughness. The goal of the experiment was to evaluate the best cutting parameter settings for achieving a smooth surface finish during CNC turning of AISI 8620 alloy steel.
IRJET- Investigation on Various Aspects of using Activated Tio2 Flux in G...IRJET Journal
1) The document investigates the use of activated TiO2 flux in gas tungsten arc welding (GTAW) of stainless steel AISI 304L to improve weld penetration and hardness.
2) Experiments were conducted using Taguchi's design of experiments to evaluate the effects of welding current, speed, and flux amount on penetration and hardness.
3) Results showed that using TiO2 flux increased penetration compared to GTAW without flux. Hardness was also slightly lower when using flux, indicating less brittleness.
This document summarizes an experimental study that optimized machining parameters for cryogenic turning of AISI 4340 steel to minimize surface roughness. The researchers used Taguchi's design of experiments methodology to test cutting speed, feed rate, depth of cut, and rake angle parameters. Analysis showed cutting speed and depth of cut most influenced surface roughness. Validation experiments confirmed the optimal parameters achieved the predicted minimum surface roughness, demonstrating cryogenic machining's ability to improve surface finish.
This document summarizes a study that used Taguchi experimental design to optimize the chemical machining parameters for cold worked stainless steel 420. The study examined the effects of machining temperature, machining time, and degree of previous cold working on the surface finish. Samples with 0%, 20%, 40%, and 60% cold working were chemically machined at temperatures of 45°C, 50°C, 55°C, and 58°C for times of 2, 4, 6, and 8 minutes. Analysis of variance and regression modeling found that the degree of previous cold working was the most significant parameter affecting surface finish. The optimal conditions were determined to be 60% cold working at 45°C for 2 minutes.
Through-Hole Exit Characteristics in Drilling Of TI6AL4V and Quality Improvem...ijmech
The removal of macro-burrs formed after drilling has always been a difficult engineering problem, especially on different-machined materials with through holes. This paper aims at presenting an investigation into hole exit characteristics of Ti6Al4V drilled. Plastic deformation at the end of the cutting process or blanking results into the forming of burr, whose degree of impact is mostly affected by the processing parameters, especially the axial feed. Series experiments were conducted to analysis the effect of processing parameter on formed burr. The volume of burr has great effect on work-piece quality and product cost, the burr height formed easily decreases because great attention from scholars and engineers has been paid to, while the burr width size despised naturally plays a great influence on product quality and machining cost. The new de-burring tool are designed and applied in experiment, the decrease in burr width is obviously found, so the removal of burrs becomes much little than that gotten in traditional tool. The resulting indicates a promising future of de-burring in practical application Journals.
The document provides a review of form drilling (also known as thermal drilling), which is a non-traditional hole making process that uses heat generated from friction between a rotating conical tool and workpiece to soften the material and form a bushing. The review discusses the basics of form drilling, technical features, applications to different materials like cast metals, the working principle involving 5 steps, and prior research studying the effects of parameters like spindle speed, feed rate, tool geometry, and workpiece material on outputs like temperature, forces, surface roughness, and bushing geometry. Key findings from previous studies investigating these relationships in materials like aluminum alloys and steel are summarized.
The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on AISI 304 stainless steel. The experiments were conducted based on Taguchi experimental design method, and the multiple performance characteristics correlated with the resultant axial force, radial force, hole diameter dimensional error, roundness error, and bushing length, were investigated by fuzzy logic technique. The significant process parameters that most intensively affected the multiple performance characteristics and the optimal combination levels of process parameters were determined through the analysis of variance and the response graph. A test rig was manufactured at Shoman Company ‒ Egypt to perform the experimental work, and the tools were offered by Flowdrill Company ‒ Germany. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process, as the bushing length produced is more than five times the workpiece thickness.
IRJET- A Review on different Approaches for Deep Drawing of Square CupIRJET Journal
The document reviews different approaches for deep drawing of square cups, including experimental, numerical, and combined experimental-numerical approaches. Experimental approaches study process parameters like punch travel, blank holding force, and diameter. Numerical approaches use finite element methods to simulate stresses, strains, and predict defects. Combined approaches validate numerical models through experiments. The optimal approach depends on drawing conditions and material behavior to achieve uniform thickness.
IRJET- Experimental Analysis and Geometrical Effect on Mild Steel with Un...IRJET Journal
This document describes an experimental analysis of drilling mild steel with both uncoated and tungsten carbide coated high-speed steel drill bits using the Taguchi technique. The experiment analyzed the impact of drilling speed, feed rate, and depth of cut on surface roughness, hole diameter, and material removal rate. Experiments were conducted on a CNC milling machine without cutting fluid. Results for the uncoated and coated drilling were collected and analyzed using Minitab software to determine the optimal drilling parameters.
Experimental Approach of CNC Drilling Operation for Mild Steel Using Taguchi...IJMER
Drilling is the most common (multi-point) cutting technique targeted for the production of
small-diameter holes. Hole making is among the most important operations in manufacturing, and
drilling is a major and common hole-making process in components. Productivity can be interpreted in
terms of material removal rate in any machining operation. It is, therefore, essential to optimize quality
and productivity simultaneously. Mild steel are soft, ductile, easily machined and is extensive used us a
main engineering material in various industry such as air craft and aerospace industry. The Taguchi
method is applied to formulate the experimental layout to ascertain the Element of impact each
optimum process parameters for CNC drilling machining with drilling operation of mild steel. A total of
27 experimental runs were conducted using an orthogonal array, and the ideal combination of
controllable factor levels was determined for the material removal rate, time of machining and
circularity has been measured. Design optimization for quality was carried out and single to noise ratio
and analysis of variance (ANOVA) were employed using experiment result to confirm effectiveness of
this approach.
THE INFLUENCE OF CUTTING SPEED VARIATION IN TURNING OF AISI 304 MATERIALS ON ...IAEME Publication
1) The study investigated the tool life and wear of coated carbide inserts when used in turning AISI 304 stainless steel at various cutting speeds.
2) The experiment found that increasing cutting speed caused faster wear growth and shorter tool life, down to 15 minutes 36 seconds at the highest speed of 225 m/min.
3) Taylor's tool life equation was determined to be VCTL0.939 = 2968 for coated carbide inserts in turning AISI 304 stainless steel based on the experimental results.
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted.
This document experimentally investigates and optimizes the micro drilling process parameters of austenitic stainless steel sheets using the Taguchi design of experiments approach. 27 experiments were conducted using a mini drilling machine to drill 0.5mm holes with varying spindle speed, feed rate, and point angle. The material removal rate was evaluated. Analysis found that feed rate had the greatest influence on material removal rate, and the optimal parameters were a spindle speed of 2000rpm, feed rate of 0.02mm, and point angle of 1260. These parameters produced the highest material removal rate and minimum tool wear during micro drilling of austenitic stainless steel sheets.
IRJET- Improving the Performance of M42 Twist Drill ToolIRJET Journal
This document summarizes an experiment to optimize the heat treatment process and improve the performance of M42 twist drill tools. The experiment tested different materials, heat treatment cycles, spindle speeds, and point angles. Testing found that M42 material exhibited the lowest wear and temperature, making it the best material. Further testing determined that a point angle of 118 degrees and spindle speed of 750 RPM provided the best performance. In total, the experiment aimed to optimize the drill tool design and heat treatment process to improve tool life, hardness, and reduce costs.
Effect of Process Parameters on Micro Hardness of Mild Steel Processed by Sur...IOSR Journals
The document discusses an experimental investigation into the effect of surface grinding process parameters on the microhardness of mild steel specimens. An experiment was conducted using a surface grinding machine to grind mild steel workpieces under different combinations of inlet coolant pressure, grinding wheel speed, workpiece speed, and nozzle angle. Microhardness measurements were then taken on the specimens. The results showed that all process parameters affected microhardness, with values ranging from 292.63 to 370.73 HV. Minimum microhardness was obtained at an inlet pressure of 25 kg/cm2, wheel speed of 2800 RPM, workpiece speed of 1.5 m/min, and nozzle angle of 6 degrees.
Studies on jet penetration and kerf width at various operating pressure in ma...eSAT Journals
Abstract Abrasive Water Jet (AWJ) machining is one of the non-traditional machining method popular method for machining of hard, heat sensitive and brittle materials. The present work attempts to investigate the effect of operating pressure on depth of penetration and kerf characteristics generated while machining of D2 heat treated steel. It is found that increase in operating pressure increases the depth of penetration and decreases the surface taper on the work-piece. Keywords: Kerf width, Depth of cut, Operating pressure, AWJ Machining
IJERD (www.ijerd.com) International Journal of Engineering Research and Devel...IJERD Editor
This document summarizes an experimental study that evaluated the effects of drill geometry and machining parameters on drilling carbon fiber reinforced plastic (CFRP) composites. The study used high-speed steel, solid carbide, and polycrystalline diamond drills to drill holes in CFRP laminates at various spindle speeds and feed rates. The results showed that drill point geometry, material, speed, and feed rate influence delamination, surface roughness, cutting forces, and chip formation. In particular, a combination of high speed and low feed rate with a drill geometry having a high point angle was found to reduce delamination.
Single-point incremental forming of sheet metal.pdfAliMElghawail
This document summarizes a study that investigated thickness distribution in single point incremental forming (SPIF) of deep drawing quality steel. A truncated cone geometry was used. A numerical simulation using ABAQUS was conducted and experimentally validated. The thickness was measured at various points along the geometry for both the simulation and physical experiment. The results showed good agreement between the simulation and experiment, with a maximum 16.1% thinning observed. It was concluded that numerical simulation can successfully predict thickness distribution and thinning in SPIF of steel sheets.
The Drill Geometry Influence on PCB Drilling PerformanceIJRES Journal
To adapt to the rapid development of PCBs, a high-property drill is desired. An applicable way is demonstrated by a design method based on analysis of drill structure, cutting force experiment , cutter wear observation to improve the drilling performance.Finally the drill wear is well improved by web thinning and chip dividing groove grinding.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
International Journal of Engineering Research and Development is an international premier peer reviewed open access engineering and technology journal promoting the discovery, innovation, advancement and dissemination of basic and transitional knowledge in engineering, technology and related disciplines.
Investigation on SS316, SS440C, and Titanium Alloy Grade-5 used as Single Poi...IJERA Editor
1. The document investigates alternative materials like SS316, SS440C, and titanium alloy grade 5 for use as single point cutting tools.
2. Experiments were conducted to compare the cutting forces, hardness, tool wear, and tool life of these materials when used as tools to machine mild steel and aluminum.
3. The results found that SS440C performed similar to high-speed steel tools for machining mild steel, making it a more cost-effective alternative. Titanium alloy provided better tool life than SS316 for machining aluminum, though SS316 could produce a better surface finish.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
The document discusses how cutting parameters affect the dimensional accuracy of circular pockets milled using CNC machines. Experiments were conducted milling pockets in aluminum, brass, and steel samples using various spindle speeds, depths of cut, and feed rates. A coordinate measuring machine (CMM) was used to measure the diameter and roundness of the machined pockets. The results showed deviations in the measurements depending on the cutting conditions and material type. The estimated expanded uncertainty in the CMM measurements was 2.4 micrometers.
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Mechanical Engineering: An International Journal (MEIJ)meijjournal
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Key insights include the importance of automation, making the adoption process seamless, and leveraging offline interactions for marketing. The presentation also emphasizes the need for continuous small improvements and building a friendly, inclusive community that contributes to the project's growth.
Vladimir Iglovikov brings his extensive experience as a Kaggle Grandmaster, ex-Staff ML Engineer at Lyft, sharing valuable lessons and practical advice for anyone looking to enhance the adoption of their open-source projects.
Explore more about Albumentations and join the community at:
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GraphSummit Singapore | The Art of the Possible with Graph - Q2 2024
INVESTIGATION OF HOLE QUALITY AND TOOL WEAR IN HIGH-SPEED DRILLING OF AL 7050
1. Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No.1/2/3/4, November 2017
DOI: 10.5121/meij.2017.4401 1
INVESTIGATION OF HOLE QUALITY AND TOOL
WEAR IN HIGH-SPEED DRILLING OF AL 7050
Edo Suryopratomo1
, Robert Heinemann2
1
Faculty of Computer Science and Engineering, Universitas Bakrie, Jakarta, Indonesia
2
School of Mechanical, Aerospace and Civil Engineering, University of Manchester,
Sackville Street, Manchester, UK
ABSTRACT
This paper investigated the feasibility of drilling aluminum 7050 with enhanced cutting speed. Two
identical tools and two identical Al-7050 work-piece plates were utilised during the experiment. Wet
cooling drilling on both conventional and high cutting speeds was conducted to compare the results. A total
of 338 holes were drilled towards the end of the experiment. Tests for tool wear, borehole diameter, and
hole quality were carried out to observe the different drilling performances by drilling with different
cutting speeds. The result shows that the proposed high speed drilling produced better diameter accuracy,
better surface roughness but poor exit burr hole tendency.
KEYWORDS
Hole quality; tool wear; burr; enhanced-speed drilling; surface roughness; hole diameter
1. INTRODUCTION
Drilling with a conventional tool at a higher cutting speed are known to bring a certain level of
implication towards hole quality and tool life [1-7]. Moreover, recent developments of aerospace
aluminum alloy (70xx series) work piece material constituent and improvement in strength might
also leads to this implication[8,1]. Generally, aluminum alloy tends to adhere to the cutting tool
surface and burrs are formed inside the holes, thereby leading to rapid tool wear[9]. This tool
damage is caused primarily by the formation of adhesion layers and built-up edges (BUE),
causing a reduction of tool life[10]. As drilling operation productivity becomes an issue,
enhancing drilling cutting speed becomes an attractive solution. However, it would possibly risk
holes quality and tool life.
A number of researchers have investigated the effect of enhancing cutting speed with respect to
hole quality and tool wear in drilling different series of aluminum alloy. However, clear resources
from literature references for a particular combination of wet condition cutting of aerospace
aluminum alloy (70xx series) at a certain cutting speed were found unavailable. Nouari et al
reported that very high-speed drilling (Vc=300m/min)of Al2024 in dry drilling condition
increases torque and thrust force which leads to the presence of a relatively large amount of
friction, rapid heat generation and chip welding. This leads to a rapid growth of adhesion layers
and built-up edges (BUE), and also chemical species diffusion. Thus resulting on rapid tool wear
rate which rapidly reduces the quality of the holes produced[1,5]. At the same paper, it was
reported that for each different type of cutting tools tested, hole diameter deviation was high at
2. Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
2
low cutting speeds (Vc<65 m/min), yet found minimum when drilling at 65m/min and inclined
when speed was increased beyond that. Astakhov reported that generally, excessive drill cutting
speed causes excessive wear of the drill periphery corners[11].
On the contrary, a few authors including Trent [10] and Aurich et al [12] suggested that
machining with an increase in cutting speed reduces the formation of BUE. Farid et al mentioned
that the decreasing amount of BUE formation was caused by the insufficient time of the deformed
chips to weld to the cutting edge, hence producing better surface finish. Moreover, thrust force
decreases with increasing cutting speed[2]. Chiffre et al identified the height and the width of the
burr were reduced at both entry and exit sides when a higher drilling cutting speed was applied on
drilling Al alloy sheet[4]. It was addressed by Abdelhafeez et al that a highly non-linear
relationship between exit burr height and the cutting parameters exist which is represented
mathematically by the second order regression [13].
As these literatures suggest different findings for different levels of high cutting speeds and
machining condition of drilling aluminum alloy, thus it is necessary to have a clear knowledge of
the hole quality and tool wear of a certain cutting speed. Within this present paper, an experiment
was performed to investigate this. The influence of enhancing cutting speed on hole surface
roughness, borehole diameter deviation, holes exit burr formation, and tool life are analyzed. A
relationship between tool-machining temperature and tool life is established.
2. EXPERIMENT SETUP
2.1 WORK-PIECE MATERIAL
The work-piece drilled in this research was aluminum alloy AA 7050-T7451 plate with material
composition given in Table 1. The material was provided by Airbus in the form of a square plate
of size 458mm (length and width) x 30 mm (height). This material was then cut in half into two
separate work-pieces, each of which will be drilled during different experimental setups.
Table 1 Chemical composition (wt%) of an AA-7050-T7451 [14]
3. Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
2.2 DRILLING TOOL
Two new identical drill tools manufactured by Klenk (
4 32/15 ) were also supplied by Airbus for the experiment. The drill was identified as an
uncoated carbide drill tool and measured as having a geometrical
length of 60 mm, diameter of 7.811 mm, two conventional cutting edges, with r
web thickness, point angle of 140
counter sink angle of 50o
. The drill tool also had two internal cooling channels, which were
irrelevant within this research since no through
images of the drill tool.
Figure 1 (a) Twist carbide drill tool utilised in this experiment (b) top view
2.3 EXPERIMENTAL EQUIPMENT
The drilling tests were executed
This machine was utilised due to its spindle speed
coolant utilised was Blasocut BS25
holes with 1 mm gap between holes
achieving the maximum number of holes
holes. An LK G90C CMM was used to measure the diameter of the drilled holes. It was
with a Renishaw PH10M touch probe with a 40mm stem length and 2mm stylus ball diameter.
This probe was suitable to measure the diameter in different depths of the drilled holes. The
measurement accuracy of this CMM is
tester was utilised to measure the drilled holes wall surface
tester has a 5µm tip radius with 0.01 µm resolution. A Jenoptik ProgRes C10 plus optical
microscope and Progress CapturePro 2 software
geometrical properties of the drill
cutting edges that occurred as drilling commence
and count was conducted in order to obtain the actual l
A Keyence VHX 500 digital microscope was utilised to observe the hole
drilled hole and also to observe a cutaway view of the drilled surface holes wall.
thermocouples was used to determine the temperature during a number of drilling cycles. For this,
a section of one of the work-piece plates was cut off, machined to provide square faces and pre
drilled with a number of holes to later accommodate the thermocouples.
2.4 EXPERIMENTAL PLANNING
The experiments were planned and conducted to evaluate and analy
• Hole diameter, hole surface
Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
Two new identical drill tools manufactured by Klenk (∅7.811 0930 15 008
) were also supplied by Airbus for the experiment. The drill was identified as an
uncoated carbide drill tool and measured as having a geometrical specification as follows: flute
length of 60 mm, diameter of 7.811 mm, two conventional cutting edges, with relatively light
web thickness, point angle of 140o
, helix angle of 20o
, with a countersink diameter of 15 mm and
. The drill tool also had two internal cooling channels, which were
irrelevant within this research since no through-coolant supply was utilised. Figure 1
(a) Twist carbide drill tool utilised in this experiment (b) top view
QUIPMENT
executed on a HAAS VF-2SS (super speed) vertical machining centre
due to its spindle speed rotation capability up to 12,000 rpm. The
coolant utilised was Blasocut BS25-MD. The drilling holes layout was designed
holes to assure that the gap between holes was minimal; thereby
maximum number of holes to be drilled, which on this plate was achieved as 338
G90C CMM was used to measure the diameter of the drilled holes. It was
uch probe with a 40mm stem length and 2mm stylus ball diameter.
This probe was suitable to measure the diameter in different depths of the drilled holes. The
measurement accuracy of this CMM is 10µm. A Taylor Hobson Surtronic 25 surface
to measure the drilled holes wall surface-roughness. The surface
tester has a 5µm tip radius with 0.01 µm resolution. A Jenoptik ProgRes C10 plus optical
and Progress CapturePro 2 software package was used to magnify and mea
drill tool and also utilised to identify the growth of tool wear on the
as drilling commence. A point to point measurement via pixel size
and count was conducted in order to obtain the actual length of the captured image on the screen.
digital microscope was utilised to observe the hole exit burr
and also to observe a cutaway view of the drilled surface holes wall.
ermine the temperature during a number of drilling cycles. For this,
piece plates was cut off, machined to provide square faces and pre
drilled with a number of holes to later accommodate the thermocouples.
LANNING
The experiments were planned and conducted to evaluate and analyze the following parameters:
Hole diameter, hole surface-roughness, exit burr formation in relation to tool life
Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
3
008 1938
) were also supplied by Airbus for the experiment. The drill was identified as an
as follows: flute
elatively light
, with a countersink diameter of 15 mm and
. The drill tool also had two internal cooling channels, which were
Figure 1 feature
vertical machining centre.
up to 12,000 rpm. The
designed as staggered
minimal; thereby
, which on this plate was achieved as 338
G90C CMM was used to measure the diameter of the drilled holes. It was equipped
uch probe with a 40mm stem length and 2mm stylus ball diameter.
This probe was suitable to measure the diameter in different depths of the drilled holes. The
Taylor Hobson Surtronic 25 surface-roughness
roughness. The surface-roughness
tester has a 5µm tip radius with 0.01 µm resolution. A Jenoptik ProgRes C10 plus optical
was used to magnify and measure
the growth of tool wear on the
point to point measurement via pixel size
image on the screen.
exit burr quality of the
and also to observe a cutaway view of the drilled surface holes wall. K-type
ermine the temperature during a number of drilling cycles. For this,
piece plates was cut off, machined to provide square faces and pre-
e the following parameters:
roughness, exit burr formation in relation to tool life
4. Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
4
• Cutting temperature (recorded in the proximity of the drilled hole)
The experiment was chosen to be performed at two different operation setups. The first setup was
a series of drilling 338 holes. A periodical stop for every 16 holes drilled was performed to
remove the tool bit from the CNC drilling center to measure its tool wear progression. The second
experiment setup was a temperature measurement by drilling with a new and worn tool at both
speeds, 3 holes each. During the experiment, the feed rate remains constant at 0.095 mm/rev, with
stroke at 39 mm. Table 2illustrates the other cutting parameters set within the experiments.
Table 2 Experimental cutting parameters
* worn tool after drilling 338 holes
Whilst the tool wear measurements were conducted “on-line”, i.e. the drilling process was
interrupted so that the tool could be taken out from the spindle and measured. The inspection of
the hole quality (diameter, surface roughness, exit burr formation) was conducted “off-line”, i.e.
once the entire plate had been drilled and could therefore been taken off the machine. Hole
diameter measurements were conducted with an interval of every 16 holes drilled, to align with
the implication of tool wear rate. For each holes being measured, measurement was taken at three
different depths, -6.3mm (below the cone), -16.3mm (middle section), and -26.3mm (located at
the bottom section of the borehole wall). At each depth, 11 touch points were recorded, which is
even beyond of what the British Standard [BS 7172, 1989] requires (which is 7 touch points).
The hole surface roughness was also measuredwith an interval of 8 to 16 holes to align with the
implication of tool wear rate. The surface roughness profile was measured in parameters of Ra,
Rz, and Rt. The measurement setup chosen was as follows: cut off value of 0.8mm, evaluation
length of 4 to 8mm, and a Gaussian filter. Two measurement locations were set: (1) for the wall
near the countersink, and (2) near the bottom wall. This method was chosen as it was reasonable
to assume that the surface finish changes with borehole wall.
3. RESULTS AND DISCUSSION
Figure 2 illustrates the tool wear and aluminum built up edge (BUE)difference on the cutting
edge of both tools.
5. Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
5
Figure 2 Digital optical magnified image (X10) of both tools cutting edge after drilling 338 holes :
(a) Tool 1 (b) Tool 2
As shown in Figure 2, BUE adhered on the cutting edge of the enhanced speed drilling was
relatively thinner compared to conventional speed drilling. This evidence was also found by Trent
[10] and Farid et al [2] which the latter stated that the formation of BUE can be attributed to the
welding of a deformed chip to the chisel edge surface at low cutting speeds. However, it did not
occur at high cutting speeds as there was insufficient time for the deformed chip to weld at the
cutting edge. BUE height measurement at different tool life is reported in Figure 3
Figure 3 Built up edge (BUE) at different tool life stages (hole 15, 175, 338) on both tools
From Figure 3, it can be depicted that by drilling with an enhanced cutting speed, aluminum BUE
grows at a slower rate. A research by Trent suggests that the disappearance of large built edge
coincided with the appearance of cratering type of wear on the rake surface of the tool, but on a
slow rate on mid-range speeds and worse above that[10]. Somehow, on this research the
appearance of this crater wear was not yet to be detected. Overall, tool wear was difficult to
observe and measure due to the dynamic shape of the cutting edge and the limited magnification
of the optical microscope. Furthermore, upon drilling 338 holes, tool wear measurements of both
tools does not show any discernable tool wear. Nevertheless, many authors suggested that
abrasive flank wear does occur at almost all speed condition. This infers that it highly likely
6. Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
6
occurred within this experiment, yet at a low level of tool wear such that it was not measurable
utilizing the chosen optical microscope[1],[10].
The measured temperature of drilling with a new tool and a worn tool at both drilling speeds, are
presented in Figure . It presents the maximum drilling temperature measured at different depths
between a new tool and worn tool, at both cutting speeds.
Figure 4 New tool and worn tool drilling temperature measured at both cutting speeds
From Figure 4 it can be observed that the temperature of the drilled hole generally increases as
the drill tool cuts from the top towards the bottom section of the hole. As suggested by Danish,
the heat continuously generates during cutting, but the cooling effect from the cutting fluid
decreases as the drill tool cuts from the top to the bottom of the hole[15].As more holes were
drilled and tool wear grows, it becomes apparent that the drilling temperature increases as a result
of additional friction from the tool wear of both cutting tools thus generating more heat compared
to drilling with a new tool.
It also appears from Figure 4that the enhanced-speed drilling produced a higher drilling
temperature. This is mainly caused by the faster strain rate and also friction which occurred
during enhanced-speed drilling, thus resulting in a more rapid heat flux generation on the
shearing plane, thus increasing the drilling temperature.
The hole diameter accuracy of both drilling speeds is presented in Figure 5.
7. Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
7
Figure 5 Measured diameter of the holes on different depths from both cutting speeds at different life stages
(hole 16, 112, 208, and 338)
From Figure 5, it can be depicted that from both cutting speeds, the diameter at the top and
middle section shows a larger diameter than at the bottom section. It can also be depicted that as
more holes were drilled, at each depths, enhanced speed cutting tends to make smaller holes,
shown by the declining slope, the opposite tendency of the conventional speed cutting. As the
drilling commences and temperature rises at higher levels as the holes get deeper, the wall of the
borehole at the bottom section retract farther than the middle and top section from the center drill
as it expands. After the temperature returns to room temperature, all the aluminum particles than
shrinks to its room temperature size thus resulting in a hole diameter smaller than the hole
diameter when it was drilled.
Figure 6 shows a cutaway view of the 1st
hole and last hole drilled of each cutting speed.
Figure 6 Cutaway view magnification drilling holes
8. Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
8
It can be observed from Figure 6 (a) and (b), the holes drilled by conventional speed produced a
rougher surface compared to enhanced speed drilling (c) and (d). The measured hole wall surface
roughness, Ra between both drilling speeds are presented in Figure 7.
Figure 7 Surface roughness (Ra) after drilling 338 holes
It can be depicted from Figure 7that the average surface roughness Ra at enhanced speed drilling
is smoother than conventional speed drilling. It is possible that the increase in temperature
expands the holes wall and also increases the wall malleability, thus causes the cutting process to
produce smoother hole walls. However, as more holes were drilled and malleability increases, the
growth in tool wear and BUE and also movements of longer chips tends to cause scratches at the
surface wall. As mentioned by Astakhov, in some cases, slow cutting speed have the effect of
burnishing the hole, creating unwanted bright spots on the hole walls, and causing tool wear[11].
The exit hole quality between both drilling speeds were also observed and it shows that only three
poor exit burrs were produced during conventional speed drilling while there were seven holes
with crown and uniform burrs produced during enhanced-speed drilling. The other remaining
holes have minimum burrs with only few microns height. Figure 8represents the exit burrs on
conventional and enhanced speed drilling, respectively.
Figure 8 Exit burr formation on both work piece
9. Mechanical Engineering: An International Journal (MEIJ), Vol. 4, No. 1/2/3/4, November 2017
9
It can be depicted from Figure 8(a) and (b), as the experiment reaches the last hole drilled, exit
burr formation becomes worse. It refers to the increase in malleability of the work-piece,
therefore, rather than cutting out the work-piece bottom surface as chips, it plastically deformed
out as burrs[12,13].This phenomenon also explains the more frequent poor burrs produced on
enhanced-speed drilling shown in Figure 8(b) due to higher elevated drilling temperature. This
causes the burrs mostly shape as thinner crown burrs especially when more tool wear and BUE
grows.
4. CONCLUSION
The drilling experiments were conducted on Aluminum Alloy AA7050 plates at both
conventional and enhanced cutting speed utilizing two identical carbide drill tools. Analysis of
the experiment result clarifies the difference in hole quality (borehole diameter, surface
roughness, exit burrs) in respect with tool life, cutting speed and drilling temperature. Overall,
enhanced speed cutting produced better diameter accuracy, better surface wall roughness with the
downside of producing thin crown burrs on the hole exit. However, tool wear was undetected due
to the limited optical microscope magnification, yeten hanced speed cutting showed a thinner
built up edge height on the cutting edge compared to conventional cutting speed.
REFERENCES
[1] List G., Girot F., Coupard D. Nouari M., "Experimental analysis and optimization of tool wear in dry
machining of aluminum alloys," Wear Journal , pp. 1359-1368, 2003.
[2] Sharif S. , Ashrafi S. A. and Mohd Farid A. A., "Statistical analysis, modelling, and optimization of
thrust force and surface roughness in high speed drilling of Al-Si alloy," Proc IMechE Part B: J
Engineering Manufacture, pp. 808–820, 2012.
[3] Soo S.L., Aspinwall D.K, Bradley S., Perry R., Harden P., Dawson S., Shyha I.S, "Hole Quality
Assessment following drilling of metallic-composite stacks," International Journal of Machine Tools
& Manufacture, pp. 569-578, 2011.
[4] Chiffre L. D., Piska M., Villumsen M. F. Lukas P, "Hole quality and burr reduction in drilling
aluminum sheets," CIRP Journal of Manufacturing Science and Technology, pp. 102–107, 2012.
[5] List G, Girot F, Géhin G. Nouari M, "Effect of machining parameters and coating," International
Journal of Machining Tools and Manufacturing, vol. 45, pp. 1436–1442, 2005.
[6] Vijayan Krishnaraj, Belkacem Sofiane Almabouacif, Francis Collombet Redouane Zitoune,
"Influence of machining parameters and new nano-coated tool on drilling," Composites: Part B, vol.
43, pp. 1480–1488, September 2011.
[7] Ahmet C., Malik K. Derzija B. H., "Experimental Study on the High Speed Machining of Hardened
Steel," Procedia Engineering, pp. 291 – 295, 2014.
[8] Starke E.A. Williams J.C., "Progress in structural materials for aerospace systems.," Acta Mater , pp.
75–99., 2003.
[9] J.M.S. Sola, J.M. Sanchez, M. Alvarez, A. Gonzalez M.S. Carrilero, "A SEM and EDS insight into
the BUL and BUE," Int. J. Machine Tools Manufacture, vol. 42 , pp. 215–220, (2002).
[10] E. M. Trent, "Tool wear and machinability," Institution of Production Engineers Journal, vol. 38, no.
6, p. 343, 1959.
[11] Viktor P Astakhov, "Drilling," in Modern Machining Technology, A practical guide.: Elsevier, 2011,
pp. 79-212.
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[12] Dornfeld D., Arrazola P.J., Franke V., Leitz L., Min S. Aurich J.C, "Burrs - analysis, control, and
removal," CIRP Annals - Manufacturing Technology 58, pp. 519-542, 2009.
[13] Soo SL, Aspinwall DK, Dowson A, Arnold D. Abdelhafeez AM, "Burr formation and hole quality
when drilling titanium and aluminum alloys," Procedia CIRP 37 CIRPe 2015 - Understanding the life
cycle implications of manufacturing, pp. 230 – 235 , 2015.
[14] N.N. (2016, Aug.) Aerospace Specification Metals Inc. [Online].
http://asm.matweb.com/search/SpecificMaterial.asp?bassnum=MA7050T745
[15] Chakarwaty Danish, "Investigation of the effectiveness of minimum quantity lubrication in deep-hole
drilling," School of Mechanical, Aerospace, and Civil Engineering University of Manchester,
Manchester, Dissertation 2014.
AUTHORS
Edo studied Mechanical Engineering at Institut Teknologi Bandung, Indonesia, obtaining the degree
Sarjana Teknik in 2010. He then worked at a local special purpose machinery equipment maker and line
integrator company appointed as head of engineering and operation documentation, working on manual and
maintenance book of each projects and also on the director monthly sales review presentation. He was also
involved on the quality system management project aimed at the workflow of the company, and later spent
time on supervising the assembly of a 3-axis CNC machine. He gained MSc in advanced manufacturing
technology and systems management from the University of Manchester in 2016, by conducting a research
project with Dr. Robert Heinemann, entitled “Investigation of Hole Quality And Tool Wear in High-Speed
Drilling of Al 7050” a project with AIRBUS. Since 2016, Edo is a lecturer at the Faculty of Engineering
and Computer Science at Universitas Bakrie.
After finishing an apprenticeship as a machine tool mechanic, Robert studied Mechanical Engineering at
the University of Paderborn at Soest, Germany, obtaining the degree Diplom Ingenieur (Dipl.-Ing. FH) in
1999. He stayed at the University as a research assistant, working at the Laboratory for Machine Tools on a
number of projects covering the areas of machine tool design, analysis and optimisaion, machining process
optimisation, as well as environmental benign machining. During this time Robert gained an MSc in
Electronic Engineering and Engineering Management from the University of Paderborn/Bolton University
in 2001 and a PhD from the University of Manchester Institute of Science and Technology in 2004. He then
continued as a Research Associate at The University of Manchester, working on various aspects of metal
cutting, with a particular interest in drilling technology, preventive tool condition monitoring for drilling,
evaluation of carbon-based coatings for the machining of titanium, as well as machine tool design and
evaluation. In 2009, Robert was awarded a 3-year Leverhulme Trust Early Career Fellowship, to conduct
research on omni-directional drilling for orthopaedic surgery. Since April 2013 Robert is a lecturer at the
School of MACE.