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.
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.
COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD ...ijmech
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
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.
COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD ...ijmech
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
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.
Analysis of process parameters in dry machining of en 31 steel by grey relati...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presentswork of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
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
Investigations on the surface roughness produced in turning of al6061 (as cas...eSAT Journals
Abstract: Surface roughness produced on the machined component is one of the key attribute of machining process. In this work the effect of various turning process parameters on surface roughness produced on Al6061 (as cast condition) is investigated. Also the effect of using coolant on surface roughness while turning is also determined. It is observed increase in cutting speed by 39.29% resulted in decrease of surface roughness by 31.44%. Increase in feed rate and depth of cut leads to increase in surface roughness. Quantitative analysis of surface roughness obtained in machining with coolant and without coolant is also presented. Keywords: Al6061, Surface Roughness, Turning Process, Spindle Speed, Depth of Cut, ANOVA
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of SAE52100 steel. Carbide inserts were used for machining of SAE 52100 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) & material removal rate of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality
products with increased productivity.
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.
Determining the influence of cutting fluids on tool wear and surface roughnes...Lepuufu
Knowledge of the performance of cutting fluids in machining different work materials is
of critical importance in order to improve the efficiency of any machining process. The
efficiency can be evaluated based on certain process parameters such as flank wear, surface
roughness on the work piece, cutting forces developed, temperature developed at the tool
chip interface, etc. The objective of this work is to determine the influence of cutting fluids
on tool wear and surface roughness during turning of AISI 304 with carbide tool. Further
an attempt has been made to identify the influence of coconut oil in reducing the tool
wear and surface roughness during turning process. The performance of coconut oil is also
being compared with another two cutting fluids namely an emulsion and a neat cutting oil
(immiscible with water). The results indicated that in general, coconut oil performed better
than the other two cutting fluids in reducing the tool wear and improving the surface finish.
Coconut oil has been used as one of the cutting fluids in this work because of its thermal
and oxidative stability which is being comparable to other vegetable-based cutting fluids
used in the metal cutting industry.
Surface residual stresses in machined austenitic stainless steelLepuufu
Surface residual stresses due to turning operations in AISI 304 type stainless steel were studied as a function of machining speed, feed rate,
depth of cut, and tool geometry and coating. Residual stress tensors were determined using X-ray diffraction technique. The effects of turning
conditions and tool on the residual stresses were discussed in terms of mechanically and thermally induced non-homogeneous plastic
deformation of the surface layers of the workpiece.
Multi-Objective Optimization ( Surface Roughness & Material Removal Rate) of ...IJERA Editor
The present study applied Taguchi method through a case study in straight turning of AISI 202 stainless steel bar on CNC Machine ( Mfd by ACE DESIGNERS) using Titanium Carbide tool for the optimization of Material removal rate, Surface Roughness and tool wear process parameter.The study aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality as well as productivity with special emphasis on maximizing material removal rate and minimizing surface roughness and tool flank wear at various combination of cutting speed, feed, depth of cut. The predicted optimal setting ensured maximum MRR and minimum surface roughness and tool wear. Since optimum material removal rate is desired, so higher the better criteria of Taguchi signal to noise ratio is used for MRR – SNs = -10 log(Sy2/n) For surface roughness and tool wear – SNL = -10 log(S(1/y2)/n) The results have been verified with the help of S/N Ratios calculation and various graphs have been plotted to show the below mentioned observations.
a) MRR first increases with increase in cutting speed and then decreases.
b) With the increase in feed, MRR increases.
c) With the increase in depth of cut, MRR first increases and then decreases.
d) With the increase in cutting speed, Surface Roughness first decreases and then increases.
e) With the increase in feed, Surface Roughness increases.
f) With the increase in depth of cut, Surface Roughness first increases and then decreases.
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.
Studies on material removal rate of al6061 while turning with coolant and wit...eSAT Journals
Abstract: Material Removal Rate (MRR) is one of the key attribute of machining process which influences productivity. In this work the effect of various turning process parameters on MRR produced on Al6061 (as cast condition) is investigated. Also, the effect of using coolant on MRR while turning is also determined. MRR is found to increase almost linearly with increase in feed rate. Increase in depth of cut and cutting speed is found to increase the MRR by 70.66 % and 16.36 % respectively. Keywords: Al6061, Material Removal Rate, Turning Process, Spindle Speed, Depth of Cut, ANOVA, Taguchi Method
Influence of tellurium addition on drilling of microalloyed steel (din 38mns6)Lepuufu
Purpose – This paper seeks to evaluate the influence of tellurium content on the machinability of the microalloyed pearlitic steel (DIN 38MnS6).
Two grades of steels were used, one with high (27 times greater) tellurium content and one with a low tellurium content. Machinability of the steel was
determined by the number of holes drilled by the tool before undergoing severe deformation. The drilling test matrix was prepared using a fractional
factorial design with five input variables studied at two levels (25-1). Other variables investigated include cutting speed (45 and 60 m/min), feed rate
(0.15 and 0.25 mm/rev), geometry of the twist drills and use of minimum quantity lubrication (MQL) at the flow rates of 30 and 100 ml/h. Statistical
analysis of the results revealed that composition of the work material was most influential on tool performance. Addition of tellurium to the steel
significantly improved machinability, increasing the number of drilled holes by over 100 per cent. The MQL flow rate was the least influential as increase
in the flow from 30 to 100 ml/h reduced drill life only by about 9 per cent.
Design/methodology/approach – The drilling tests were carried out in the vertical position, up-down, without pre-holes (full drilling). Cutting
speeds of 45 and 60 m/min and feed rates of 0.15 and 0.25 mm/rev were employed. Drills with two sharpening types were tested. Cutting fluid used
was vegetable based and applied using the MQL technique at flow rates of 30 and 100 ml/h. The rejection criterion adopted was severe deformation of
the drills and the number of machined holes was used to measure the machinability of the material.
Findings – Of all the variables investigated in this study, the least influential on drill performance is the MQL flow rate. Increase in the flow rate from
30 to 100 ml/h reduced drill performance by 9 per cent, contrary to expectation. This is a result of the cooling-lubricant action balance promoted by the
cutting fluid applied in low quantities (MQL). The most influential variable on drill performance is addition of Te to the work material which gave over
twofold (103 per cent) improvement in drill performance at the cutting conditions investigated. The Te particles act at the chip-tool interface, reducing
the work necessary to shear the material during chip formation. Increase in both the cutting speed and the feed rate both lowered drill performance
during machining due to associated increase in cutting temperature which tended to accelerate thermally related wear mechanisms.
Originality/value – This work was conducted to evaluate the machinability of a novel alloyed steel employed in the automobile industry. Drilling was
considered as most automobile components especially the engine block is designed with many holes which require drilling process.
20 Ideas for your Website Homepage ContentBarry Feldman
Perplexed about what to put on your website home? Every company deals with this tough challenge. The 20 ideas in this presentation should give you a strong starting point.
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.
Analysis of process parameters in dry machining of en 31 steel by grey relati...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presentswork of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
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
Investigations on the surface roughness produced in turning of al6061 (as cas...eSAT Journals
Abstract: Surface roughness produced on the machined component is one of the key attribute of machining process. In this work the effect of various turning process parameters on surface roughness produced on Al6061 (as cast condition) is investigated. Also the effect of using coolant on surface roughness while turning is also determined. It is observed increase in cutting speed by 39.29% resulted in decrease of surface roughness by 31.44%. Increase in feed rate and depth of cut leads to increase in surface roughness. Quantitative analysis of surface roughness obtained in machining with coolant and without coolant is also presented. Keywords: Al6061, Surface Roughness, Turning Process, Spindle Speed, Depth of Cut, ANOVA
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of SAE52100 steel. Carbide inserts were used for machining of SAE 52100 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) & material removal rate of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality
products with increased productivity.
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.
Determining the influence of cutting fluids on tool wear and surface roughnes...Lepuufu
Knowledge of the performance of cutting fluids in machining different work materials is
of critical importance in order to improve the efficiency of any machining process. The
efficiency can be evaluated based on certain process parameters such as flank wear, surface
roughness on the work piece, cutting forces developed, temperature developed at the tool
chip interface, etc. The objective of this work is to determine the influence of cutting fluids
on tool wear and surface roughness during turning of AISI 304 with carbide tool. Further
an attempt has been made to identify the influence of coconut oil in reducing the tool
wear and surface roughness during turning process. The performance of coconut oil is also
being compared with another two cutting fluids namely an emulsion and a neat cutting oil
(immiscible with water). The results indicated that in general, coconut oil performed better
than the other two cutting fluids in reducing the tool wear and improving the surface finish.
Coconut oil has been used as one of the cutting fluids in this work because of its thermal
and oxidative stability which is being comparable to other vegetable-based cutting fluids
used in the metal cutting industry.
Surface residual stresses in machined austenitic stainless steelLepuufu
Surface residual stresses due to turning operations in AISI 304 type stainless steel were studied as a function of machining speed, feed rate,
depth of cut, and tool geometry and coating. Residual stress tensors were determined using X-ray diffraction technique. The effects of turning
conditions and tool on the residual stresses were discussed in terms of mechanically and thermally induced non-homogeneous plastic
deformation of the surface layers of the workpiece.
Multi-Objective Optimization ( Surface Roughness & Material Removal Rate) of ...IJERA Editor
The present study applied Taguchi method through a case study in straight turning of AISI 202 stainless steel bar on CNC Machine ( Mfd by ACE DESIGNERS) using Titanium Carbide tool for the optimization of Material removal rate, Surface Roughness and tool wear process parameter.The study aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality as well as productivity with special emphasis on maximizing material removal rate and minimizing surface roughness and tool flank wear at various combination of cutting speed, feed, depth of cut. The predicted optimal setting ensured maximum MRR and minimum surface roughness and tool wear. Since optimum material removal rate is desired, so higher the better criteria of Taguchi signal to noise ratio is used for MRR – SNs = -10 log(Sy2/n) For surface roughness and tool wear – SNL = -10 log(S(1/y2)/n) The results have been verified with the help of S/N Ratios calculation and various graphs have been plotted to show the below mentioned observations.
a) MRR first increases with increase in cutting speed and then decreases.
b) With the increase in feed, MRR increases.
c) With the increase in depth of cut, MRR first increases and then decreases.
d) With the increase in cutting speed, Surface Roughness first decreases and then increases.
e) With the increase in feed, Surface Roughness increases.
f) With the increase in depth of cut, Surface Roughness first increases and then decreases.
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.
Studies on material removal rate of al6061 while turning with coolant and wit...eSAT Journals
Abstract: Material Removal Rate (MRR) is one of the key attribute of machining process which influences productivity. In this work the effect of various turning process parameters on MRR produced on Al6061 (as cast condition) is investigated. Also, the effect of using coolant on MRR while turning is also determined. MRR is found to increase almost linearly with increase in feed rate. Increase in depth of cut and cutting speed is found to increase the MRR by 70.66 % and 16.36 % respectively. Keywords: Al6061, Material Removal Rate, Turning Process, Spindle Speed, Depth of Cut, ANOVA, Taguchi Method
Influence of tellurium addition on drilling of microalloyed steel (din 38mns6)Lepuufu
Purpose – This paper seeks to evaluate the influence of tellurium content on the machinability of the microalloyed pearlitic steel (DIN 38MnS6).
Two grades of steels were used, one with high (27 times greater) tellurium content and one with a low tellurium content. Machinability of the steel was
determined by the number of holes drilled by the tool before undergoing severe deformation. The drilling test matrix was prepared using a fractional
factorial design with five input variables studied at two levels (25-1). Other variables investigated include cutting speed (45 and 60 m/min), feed rate
(0.15 and 0.25 mm/rev), geometry of the twist drills and use of minimum quantity lubrication (MQL) at the flow rates of 30 and 100 ml/h. Statistical
analysis of the results revealed that composition of the work material was most influential on tool performance. Addition of tellurium to the steel
significantly improved machinability, increasing the number of drilled holes by over 100 per cent. The MQL flow rate was the least influential as increase
in the flow from 30 to 100 ml/h reduced drill life only by about 9 per cent.
Design/methodology/approach – The drilling tests were carried out in the vertical position, up-down, without pre-holes (full drilling). Cutting
speeds of 45 and 60 m/min and feed rates of 0.15 and 0.25 mm/rev were employed. Drills with two sharpening types were tested. Cutting fluid used
was vegetable based and applied using the MQL technique at flow rates of 30 and 100 ml/h. The rejection criterion adopted was severe deformation of
the drills and the number of machined holes was used to measure the machinability of the material.
Findings – Of all the variables investigated in this study, the least influential on drill performance is the MQL flow rate. Increase in the flow rate from
30 to 100 ml/h reduced drill performance by 9 per cent, contrary to expectation. This is a result of the cooling-lubricant action balance promoted by the
cutting fluid applied in low quantities (MQL). The most influential variable on drill performance is addition of Te to the work material which gave over
twofold (103 per cent) improvement in drill performance at the cutting conditions investigated. The Te particles act at the chip-tool interface, reducing
the work necessary to shear the material during chip formation. Increase in both the cutting speed and the feed rate both lowered drill performance
during machining due to associated increase in cutting temperature which tended to accelerate thermally related wear mechanisms.
Originality/value – This work was conducted to evaluate the machinability of a novel alloyed steel employed in the automobile industry. Drilling was
considered as most automobile components especially the engine block is designed with many holes which require drilling process.
20 Ideas for your Website Homepage ContentBarry Feldman
Perplexed about what to put on your website home? Every company deals with this tough challenge. The 20 ideas in this presentation should give you a strong starting point.
10 Insightful Quotes On Designing A Better Customer ExperienceYuan Wang
In an ever-changing landscape of one digital disruption after another, companies and organisations are looking for new ways to understand their target markets and engage them better. Increasingly they invest in user experience (UX) and customer experience design (CX) capabilities by working with a specialist UX agency or developing their own UX lab. Some UX practitioners are touting leaner and faster ways of developing customer-centric products and services, via methodologies such as guerilla research, rapid prototyping and Agile UX. Others seek innovation and fulfilment by spending more time in research, being more inclusive, and designing for social goods.
Experience is more than just an interface. It is a relationship, as well as a series of touch points between your brand and your customer. Here are our top 10 highlights and takeaways from the recent UX Australia conference to help you transform your customer experience design.
For full article, continue reading at https://yump.com.au/10-ways-supercharge-customer-experience-design/
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Learn BEM fundamentals as fast as possible. What is BEM (Block, element, modifier), BEM syntax, how it works with a real example, etc.
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ANALYSIS OF PROCESS PARAMETERS IN DRY MACHINING OF EN-31 STEEL by GREY RELATI...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth o f cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presents work of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
Full factorial method for optimization of process parameters for surface roug...Editor IJMTER
Quality and productivity play significant role in today’s manufacturing market.In
machining operations, achieving desired surface quality features of the machined product, is really a
challenging job on cnc machine. Because, these quality features are highly correlated and are
expected to be influenced directly or indirectly by the direct effect of process parameters. There are a
number of parameters like cutting speed, feed and depth of cut etc. which must be given
consideration during the machining of SS 316L. The prediction of optimal machining conditions for
good surface roughness and material removal rate plays a very important role in process planning.
Experimental Investigation of Effect of Tool Length on Surface Roughness duri...IOSR Journals
: In the turning operation, vibration is a frequent problem, which affects the result of the machining
and in particular the surface finish. Tool life is also influenced by vibrations. Severe acoustic noise in the
working environment frequently results as a dynamic motion between the cutting tool and the work piece. In all
cutting operations like turning, boring and milling vibrations are induced due to deformation of the work piece.
In the turning process, the importance of machining parameter choice is increased, as it controls the surface
quality required. Tool overhang is a cutting tool parameter that has not been investigated in as much detail as
some of the better known ones. It is appropriate to keep the tool overhang as short as possible; however, a
longer tool overhang may be required depending on the geometry of the work piece and when using the holeturning
process in particular. In this study, we investigate the effects of changes in the tool overhang in the
external turning process on both the surface quality of the work piece and tool wear. For this purpose, we used
work pieces of AISI 1050 material with diameters of 20, 30, and 40 mm; and the surface roughness of the work
piece were determined through experiments using constant cutting speed and feed rates with different depth of
cuts (DOCs) and tool overhangs. We observed that the effect of the DOC on the surface roughness is negligible,
but tool overhang is more important. The deflection of the cutting tool increases with tool overhang. Two
different analytical methods were compared to determine the dependence of tool deflection on the tool
overhang. Also, the real tool deflection values were determined using a comparator. We observed that the tool
deflection values were quite compatible with the tool deflection results obtained using the second analytical
method.
Determining the Influence of Various Cutting Parameters on Surface Roughness ...IOSR Journals
The purpose of this experimental investigation was to analyse the effect of controlled cutting
parameters namely cutting speed, feed rate, depth of cut, cutting fluid concentration and two cutting fluids with
different base oils on surface roughness (Ra) of EN8 or AISI 1040 steel during turning operation by applying
design of experiments, custom design method, analysis of variance, leverage plots and desirability profiling
using JMP software to optimize surface roughness during wet CNC turning operation. The analysis reveals that
feed rate has the most significant effect on surface roughness (Ra) and value of surface roughness does not
significantly differ for two different cutting fluids used.
A review on effect of various parameters on cutting tool in orthogonal metal ...eSAT Journals
Abstract
In recent years there is great progress in the field of tool design. Tool is an important factor for machinability process. In the
metal cutting process various cutting parameters affecting on the cutting tool. The various parameters include as cutting speed,
feed rate, depth of cut, rake angle. The effect of these parameters on the cutting forces, tool temperature, and surface roughness
studied. This helps in evaluating the tool life and tool wear. This effect of parameters on tool is important for efficient machining
and machining conditions. The paper also covers the effect of cutting parameters on the chip formation and residual stresses
produced during cutting process.
Keywords: Cutting parameters, orthogonal, cutting process, cutting tool
optimization of process parameters for cnc turning using taguchi methods for ...INFOGAIN PUBLICATION
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T4201135138
1. Jigar Patel et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.135-138
RESEARCH ARTICLE
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OPEN ACCESS
A Review on Parametric Optimization of Surface Roughness &
Material Remove Rate of AISI D2 Steel Using Turning
Hitesh Patel*, Jigar Patel**, Chandresh Patel***
* PG Fellow,
** Assistant Professor
*** Assistant Professor
Department of Mechanical Engineering, S.P.B.Patel Engineering College, Mehsana, Gujarat
ABSTRACT
In order to produce any product with desired quality by machining, proper selection of process parameters is
essential. This can be accomplished by Full Factorial method. The aim of the present work is to investigate the
effect of process parameter on surface finish and material removal rate (MRR) to obtain the optimal setting of
these process parameters and the analysis of variance is also used to analysis the influence of cutting parameters
during machining. L27 experimental will run based on an orthogonal array of full factorial method. Additionally
the analysis of variance (ANOVA) will also apply to identify the most significant factor. During the
experimental process parameters such as speed, feed and depth of cut are used to explore their effect on the
surface roughness (Ra) of the work piece. This work will present an experimental investigation of influence of
the three most important machining parameters of Speed, Feed and Depth of Cut on surface roughness during
turning of AISI D2 steel. In this work AISI D2 steel work pieces are turned on conventional all gear lathe by
using carbide tool.
Keywords - Full Factorial Method, Machining Parameters, Surface Roughness, Material Removal Rate (MRR),
ANOVA Analysis
I.
INTRODUCTION
A Lathe is a machine tool used principally
for shaping pieces of metal, wood, or other materials
by causing the workpiece to be held and rotated by
the lathe while a tool bit is advanced into the work
causing the cutting action. Lathes can be divided into
three types for easy identification: engine lathe, turret
lathe, and special purpose lathes. Some smaller ones
are bench mounted and semi-portable. The larger
lathes are floor mounted and may require special
transportation if they must be moved. Field and
maintenance shops generally use a lathe that can be
adapted to many operations and that is not too large
to be moved from one work site to another.
Turning is a machining process in which a
cutting tool, typically a non-rotary toolbit, describes a
helical tool path by moving more or less linearly
while the workpiece rotates. The tool's axes of
movement may be literally a straight line, or they
may be along some set of curves or angles, but they
are essentially linear (in the nonmathematical sense).
Usually the term "turning" is reserved for the
generation of external surfaces by this cutting action,
whereas this same essential cutting action when
applied to internal surfaces (that is, holes, of one kind
or another) is called "boring". Fig. 1 shows the
turning operation.
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Fig.1. Turning Operation
Cutting speed in turning V in m/s is related
to the rotational speed of the workpiece by the
equation;
V = πDN
Where D is the diameter of the workpiece; N
is the rotational speed of the workpiece. The three
primary factors in any basic turning operation are
speed, feed, and depth of cut.
In our project we are going to use AISI D2
tool steel which also known as HCHC tool steel. The
135 | P a g e
2. Jigar Patel et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.135-138
chemical composition of AISI D2 tool steel is given
in below Table 1.
Table 1. Chemical Composition
Carbon
1.55%
Silicon
0.30%
Manganese
0.35%
Chromium
12.00%
12.00%
0.75%
Molybdenum
Vanadium
0.90%
AISI D2is recommended for tools requiring
very high wear resistance, combined with moderate
toughness (shock-resistance).AISI D2can be supplied
in various finishes, including the hot-rolled, premachined and fine machined condition. Forming
Dies, Punches,
Forming Rolls, Knives, Slitters,
Shear blades.
II.
LITERATURE REVIEW
There are many articles are published on
parametric optimization. Not all the articles are
directly related to our work, especially, those articles
which were focused on computational work. Many
articles addressed experimental and theoretical
optimization processes discussed. In this subsection,
we are going to discuss only those articles
(experimental and/or theoretical work) which are
directly related to current work.
M. Kaladhar et al. (2011) investigate the effects of
process parameters on surface finish and material
removal rate (MRR) to obtain the optimal setting of
these process parameters on AISI 304 steel. The
Analysis Of Variance (ANOVA) is also used to
analyze the influence of cutting parameters during
machining. The results revealed that the feed and
nose radius is the most significant process parameters
on work piece surface roughness. However, the depth
of cut and feed are the significant factors on MRR.[1]
Muammer Nalbant et al. (2007) investigate the
effects of machining of AISI 1030 steel (i.e.
orthogonal cutting) uncoated, PVD- and CVD-coated
cemented carbide insert with different feed rates,
cutting speeds by keeping depth of cuts constant
without using cooling liquids has been accomplished.
The surface roughness effects of coating method,
coating material, cutting speed and feed rate on the
work piece have been investigated. In this
experimental study, an ANN-based prediction
mechanism which removes the necessity of
regression analysis has been presented. The
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conclusion shows that there is a negative relationship
between the average surface roughness and cutting
speed of coated cemented carbide cutting tools.
Increasing the cutting speed reduces the average
surface roughness. In the case of uncoated cemented
carbide cutting tools there is parallel relationship
between the cutting speed and average surface
roughness value. Increasing the cutting speed also
increases the average surface roughness. [2]
Anil Gupta et al. (2011)presents the application of
Taguchi method with logical fuzzy reasoning for
multiple output optimization of high speed CNC
turning of AISI P-20 tool steel using TiN coated
tungsten carbide coatings. The machining parameters
(cutting speed, feed rate, depth of cut, nose radius
and cutting environment) are optimized with
considerations of the multiple performance measures
(surface roughness, tool life, cutting force and power
consumption). Taguchi’s concepts of orthogonal
arrays, signal to noise (S/N) ratio, ANOVA have
been fuzzified to optimize the high speed CNC
turning process parameters through a single
comprehensive output measure (COM). It can be
concluded that middle level of cutting speed and nose
radius and lower level of feed and depth of cut yield
the optimal result. Cryogenic environment is the most
favorable condition out of three cutting
environments. [3]
B FNIDE et al. (2010) investigate the application of
response surface methodology for determining
statistical models of cutting forces in hard turning of
AISI H11 hot work tool steel. The work piece is
machined by a mixed ceramic tool (insert CC650 of
chemical composition 70%Al2O3+30%TiC) under
dry conditions. Based on 33 full factorial design, a
total of 27 tests were carried out. Mathematical
models were deduced by software Minitab (multiple
linear regression and response surface methodology)
in order to express the influence degree of the main
cutting variables such as cutting speed, feed rate and
depth of cut on cutting force components. The results
indicate that the depth of cut is the dominant factor
affecting cutting force components. The feed rate
influences tangential cutting force more than radial
and axial forces. The cutting speed affects radial
force more than tangential and axial forces. [4]
Sukumar et al. (2012) investigate the effects of
machining parameter on CNC turning of martensitic
stainless steel using RSM(Response surface
methodology) and GA( Genetic algorithm). The
results obtained from RSM are R-Sq obtained was
99.9% which indicates that selected parameters
(speed, feed, depth of cut) significantly affect the
response (surface roughness). [5]
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3. Jigar Patel et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.135-138
Yansong Guo et al. (2012) investigate the effects of
an approach which incorporates both energy
consumption and surface roughness is presented for
optimizing the cutting parameters in finish turning.
Based on a new energy model and a surface
roughness model, derived for a given machine tool,
cutting parameters are optimized to accomplish a
precise surface finish with minimum energy
consumption. The analysis reveals that a two-step
approach in determining the optimal cutting
parameters for finishing turning operations for
minimal energy consumption, by guaranteeing a
specified surface roughness. [6]
Gaurav Bartarya et al. (2012) investigate effect of
cutting parameters on cutting force and surface
roughness during finish hard turning AISI52100
grade steel. A full factorial design of experiments
procedure was used to develop the force and surface
roughness regression models, within the range of
parameters selected. The regression models
developed show that the dependence of the cutting
forces i.e. cutting, radial and axial forces and surface
roughness on machining parameters are significant,
hence they could be used for making predictions for
the forces and surface roughness. The predictions
from the developed models were compared with the
measured force and surface roughness values. To test
the quality of fit of data, the ANOVA analysis was
undertaken. It has been conclude that Depth of cut
was found to be the most influential parameter
affecting the three cutting forces followed by the
feed. Cutting speed was least significant in case of
axial and radial force models but was not significant
forthe regression model of cutting force. For the
surface roughness predictions, the model developed
from the analysis was found insignificant. [7]
Suleiman Abdulkareem et al. (2011) investigate of
the influence of the three most important machining
parameters of depth of cut, feed rate and spindle
speed on surface roughness during turning of mild
steel. In this study, the design of experiment which is
a powerful tool for experimental design is used to
optimize the machining parameters for effective
machining of the work piece. Box Behnken
experimental design method as well as analysis of
variance (ANOVA) is used to analyze the influence
of machining parameters on surface roughness height
Ra. Using multiple linear regressions, mathematical
models correlating the influence of machining
parameters on the surface roughness Ra during the
machining process were developed. The result shows
that the feed rate is found to be the most important
parameter effecting Ra, followed by cutting speed
while spindle speed has the least effect. [8]
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R.A. Mahdavinejad et al. (2011) investigate paper
the optimize turning parameters of AISI 304 stainless
steel. Turning tests have been performed in three
different feed rates, cutting speeds with and without
cutting fluid. A design of experiments (DOE) and an
analysis of variance (ANOVA) have been made to
determine the effects of each parameter on the tool
wear and the surface roughness. It is being inferred
that cutting speed has the main influence on the flank
wear and as it increases, the flank wear decreases.
The feed rate has the most important influence on the
surface roughness and as it decreases, the surface
roughness also decreases. Also, the application of
cutting fluid results in longer tool life and better
surface finish. [9]
Pragnesh. R. Patel(2012) investigate the effects of
different cutting parameters (Cutting Speed, feed
rate, Depth of cut) on surface roughness and Power
Consumption in turning of 6063 AL alloy TiC
(MMCs). PCD tool was used as wear resistive tool in
order to achieve desire surface finish. Full factorial
Design in design of experiment was adopted in order
to planning the experimental runs. Analysis of
Variance was used to investigate percentage
Contribution of Each process parameters on output
Response. Results show that feed rate is significant
parameter, which affect on surface roughness; and
Cutting Speed is effective parameter which affect on
power consumption. [10]
Kamal Hassan et al. (2012) investigates the effects
of process parameters on Material Removal Rate
(MRR) in turning of C34000.The effect of
parameters i.e Cutting speed, feed rate and depth of
cut and some of their interactions were evaluated
using ANOVA analysis with the help of MINITAB
16 @ software. And it has been conclude that The
Material removal rate is mainly affected by cutting
speed and feed rate. The conclusion shoes that with
the increase in cutting speed the material removal
rate is increases & as the feed rate increases the
material removal rate is increases. [11]
III.
CONCLUSION
A From the above literature survey we find
that there are many research done on optimization
techniques for process parameter for surface
roughness and material removal rate. But I found that
there are very few research done on AISI D2 tool
steel so we want to do research on this material. We
like to use gray relational analysis for optimization.
REFERENCES
[1]
M. Kaladhar, K. Venkata Subbaiah, Ch.
Srinivasa Rao. “Determination of Optimum
Process Parameters during turning of AISI
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4. Jigar Patel et al Int. Journal of Engineering Research and Applications
ISSN : 2248-9622, Vol. 4, Issue 2( Version 1), February 2014, pp.135-138
304 Austenitic Stainless Steels using Taguchi
method and ANOVA” International Journal
of Lean Thinking Volume 3, Issue 1 (June
2012) pp.1-19.
[2]
Muammer Nalbant, Hasan Gokkaya, Ihsan
Toktas, Gokhan Sur. “The experimental
investigation of the effects of uncoated,
PVD- and CVD-coated cemented carbide
inserts and cutting parameters on surface
roughness in CNC turning and its prediction
using artificial neural networks” Robotics
and Computer-Integrated Manufacturing 25
(2009) pp.211–223.
[3]
Anil Gupta, Hari Singh, Aman Aggarwal.
“Taguchi-fuzzy multi output optimization
(MOO) in high speed CNC turning of AISI
P-20 tool steel” Expert Systems with
Applications 38 (2011) pp.6822–6828.
[4]
B Fnides, M A Yallese, T Mabrouki, J F
Rigal. “Application of response surface
methodology for determining cutting force
model in turning hardened AISI H11 hot
work tool steel” Sadhana Vol. 36, Part 1
(2011) pp.109–123.
[5]
Sukumar, Poornima. “Optimization of
machining parameters in CNC turning of
martensitic stainless steel using RSM and
GA” International Journal of Modern
Engineering Research (IJMER) Vol.2,
Issue.2, (Apr. 2012) pp.539-542.
[6]
Yansong Guo, Jef Loenders, Joost Duflou,
Bert Lauwers. “Optimization of energy
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[7]
[8]
[9]
[10]
[11]
www.ijera.com
consumption and surface quality in finish
turning” Procedia CIRP 1 ( 2012 ) pp.529 –
534.
Gaurav Bartarya, S.K.Choudhury. “Effect of
cutting parameters on cutting force and
surface roughness during finish hard turning
AISI52100 grade steel” Procedia CIRP 1
(2012) pp.674 – 679.
Suleiman Abdulkareem, Usman Jibrin
Rumah, Apasi Adaokoma. “Optimizing
Machining Parameters during Turning
Process” International Journal of Integrated
Engineering, Vol. 3 No. 1 (2011) pp.23-27.
R A Mahdavinejad, S Saeedy. “Investigation
of the influential parameters of machining of
AISI 304 stainless steel” Sadhana Vol. 36,
Part 6 (2011) pp.963–970.
Pragnesh. R. Patel, Prof. V. A. Patel. “Effect
of machining parameters on Surface
roughness and Power consumption for 6063
Al alloy TiC Composites (MMCs)”
International Journal of Engineering
Research and Applications Vol. 2 (2012)
pp.295-300.
Kamal Hassan, Anish Kumar, M.P.Garg.
“Experimental investigation of Material
removal rate in CNC turning using Taguchi
method”
International
Journal
of
Engineering Research and Applications Vol.
2 (2012) pp.1581-1590.
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