The Experts below are selected from a list of 14757 Experts worldwide ranked by ideXlab platform
Paulo J Davim - One of the best experts on this subject based on the ideXlab platform.
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machinability analysis in turning tungsten copper composite for application in edm electrodes
International Journal of Refractory Metals & Hard Materials, 2010Co-Authors: V N Gaitonde, S. R. Karnik, M Faustino, Paulo J DavimAbstract:Abstract Electro-discharge Machining (EDM) is widely used in tooling industry, where it is applied on materials, which are too hard to be machined with conventional techniques. The tungsten–copper is broadly used as an EDM electrode for Machining of die steel and tungsten carbide workpieces. As, tungsten–copper electrode is more costly than conventional electrodes, there is a need to understand the machinability aspects in turning of this material. Hence, an attempt has been made in this paper to study the effects of cutting conditions on machinability characteristics such as cutting Force, feed Force, depth Force, Machining Force, power, specific cutting Force, arithmetic average surface roughness and maximum peak to valley height during tungsten–copper turning with K10 carbide cutting tool. The response surface methodology (RSM) based second order mathematical models of machinability aspects are developed using the data obtained through full factorial design (FFD). The adequacy of the machinability models is tested through the analysis of variance (ANOVA). The response surface analysis reveals that a combination of higher cutting speed with low-to-medium feed rate is advantageous in reducing the Forces, power and surface roughness, which in turn increases the specific cutting Force.
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analysis of machinability during hard turning of cold work tool steel type aisi d2
Materials and Manufacturing Processes, 2009Co-Authors: V N Gaitonde, S. R. Karnik, Luis Figueira, Paulo J DavimAbstract:Hard turning is an attractive replacement for grinding operations due to numerous advantages such as low capital investment, shorter setup time, higher material removal rate, better surface integrity, and elimination of cutting fluids. As a potential alternative process, there is a need to assess the machinability in high-precision and high-hardened components. The current study establishes the relationships between the cutting conditions (cutting speed, feed rate, and Machining time) on machinability aspects (Machining Force, power, specific cutting Force, surface roughness, and tool wear). The response surface methodology-based mathematical models are proposed for modeling and analyzing the effects of process parameters on machinability during turning of high chromium AISI D2 cold work tool steel using CC650WG wiper ceramic inserts. The experiments have been planned as per full factorial design. From the parametric analysis, it is revealed that the power increases with increase in feed rate, while the s...
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some studies in metal matrix composites Machining using response surface methodology
Journal of Reinforced Plastics and Composites, 2009Co-Authors: V N Gaitonde, S. R. Karnik, Paulo J DavimAbstract:The present study establishes the relationship between cutting conditions and machinability characteristics during the turning of metal matrix composites (MMC). The investigation aims at determining the effects of cutting speed and feed rate on Machining Force, cutting power, and specific cutting Force by developing second-order mathematical models using response surface methodology (RSM). Aluminum alloy reinForced with 20% of SiC particulates (A 356/20/SiCp-T6) were machined using a polycrystalline diamond (PCD) tool. The experiments have been planned as a full factorial design of experiments (FFD). The analysis of variance (ANOVA) was performed to check the adequacy of the mathematical models. The parametric analysis reveals that the Machining Force and cutting power increase with increase in feed rate while the specific cutting Force decreases.
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machinability investigations in hard turning of aisi d2 cold work tool steel with conventional and wiper ceramic inserts
International Journal of Refractory Metals & Hard Materials, 2009Co-Authors: V N Gaitonde, S. R. Karnik, Luis Figueira, Paulo J DavimAbstract:Hard turning with ceramic cutting tool has several benefits over grinding process such as elimination of coolant, reduced processing costs, improved material properties, reduced power consumption and increased productivity. Despite its significant advantages, hard turning can not replace all grinding due to lack of data concerning surface quality and tool wear and hence there is a need to study the machinability characteristics in high precision and high-hardened components. An attempt has been made in this paper to analyze the effects of depth of cut and Machining time on machinability aspects such as Machining Force, power, specific cutting Force, surface roughness and tool wear using second order mathematical models during turning of high chromium AISI D2 cold work tool steel with CC650, CC650WG and GC6050WH ceramic inserts. The experiments were planned as per full factorial design (FFD). From the parametric analysis, it is revealed that, the CC650WG wiper insert performs better with reference to surface roughness and tool wear, while the CC650 conventional insert is useful in reducing the Machining Force, power and specific cutting Force.
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a study on milling of glass fiber reinForced plastics manufactured by hand lay up using statistical analysis anova
Composite Structures, 2004Co-Authors: Paulo J Davim, Pedro Reis, Carlos Alberto Conceicao AntonioAbstract:Milling is the most practical Machining (corrective) operation for removing excess material to produce a well defined and high quality surface. However, milling composite materials presents a number of problems such as surface delamination associated with the characteristics of the material and the cutting parameters used. In order to minimize these problem is presented a study with the objective of evaluating the cutting parameters (cutting velocity and feed rate) related to Machining Force in the workpiece, delamination factor, surface roughness and international dimensional precision in two GFRP composite materials (Viapal VUP 9731 and ATLAC 382-05). A plan of experiments, based on an orthogonal array, was established considering milling with prefixed cutting parameters. Finally an analysis of variance (ANOVA) was preformed to investigate the cutting characteristics of GFRP composite materials using a cemented carbide (K10) end mill.
Steven Y. Liang - One of the best experts on this subject based on the ideXlab platform.
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grain size sensitive mts model for ti 6al 4v Machining Force and residual stress prediction
The International Journal of Advanced Manufacturing Technology, 2019Co-Authors: Zhipeng Pan, Hamid Garmestani, Steven Y. Liang, Peter J BocchiniAbstract:Material properties are significantly influenced by the parameters of the Machining process. The accurate prediction of Machining Force and residual stress reduces power consumption, enhances material properties, and improves dimensional accuracy of the finished product. Traditional method using the finite element analysis (FEA) costs a significant amount of time, and the archived mechanical threshold stress (MTS) model without consideration of microstructure of the material yields inaccurate result. In this paper, a grain size–sensitive MTS model is introduced for the Machining process of Ti-6Al-4V. A grain size–sensitive term is introduced to the modified MTS model to account for evolution of the grain size. The grain size–sensitive MTS model takes the microstructure of the Ti-6Al-4V into consideration for the calculation of Machining Force and residual stress. The grain size–sensitive term is introduced into the athermal stress component using the initial yield stress, strain hardening coefficient, and the Hall-Petch coefficient. The analytical result is compared with those of experimental studies and the traditional Johnson-Cook model to prove the validity in the prediction of Machining Force and residual stress. The proposed model explores a new area for calculating cutting Forces and residual stress.
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inverse determination of johnson cook model constants of ultra fine grained titanium based on chip formation model and iterative gradient search
The International Journal of Advanced Manufacturing Technology, 2018Co-Authors: Jinqiang Ning, Vinh Nguyen, Yong Huang, K T Hartwig, Steven Y. LiangAbstract:This paper presents an original method to inversely identify the Johnson–Cook model constants (J-C constants) of ultra-fine-grained titanium (UFG Ti) based on a chip formation model and an iterative gradient search method using Kalman filter algorithm. UFG Ti is increasingly finding usefulness in lightweight engineering applications and medical implant filed because of its sufficient mechanical strength, high manufacturability, and high biocompatibility. Johnson–Cook model is one of the constitutive models widely used in analytical modeling of Machining Force, temperature, and residual stress because it is effective, simple, and easy to use. Currently, the J-C constants of UFG Ti are unavailable and yet an effective identification methodology based upon Machining data is not readily available. In this work, multiple cutting tests were conducted under different cutting conditions, in which Machining Forces were experimentally measured using a piezoelectric dynamometer. The Machining Forces were also predicted using the chip formation model with inputs of cutting conditions, workpiece material properties, and a set of given model constants. An iterative gradient search method was enForced to find the J-C constants when the difference between predicted Forces and experimental Forces reached an acceptable low value. To validate the identified J-C constants, Machining Forces were predicted using the identified J-C constants under different cutting conditions and then compared to the corresponding experimental Forces. Close agreements were observed between predicted Forces and experimental Forces. Considering the simple orthogonal cutting tests, reliable and easily measurable Machining Forces, and efficient iterative gradient search method, the proposed method has less experimental complexity and high computational efficiency.
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predicting the effects of cutting fluid on Machining Force temperature and residual stress using analytical method
Journal of Computer Applications in Technology, 2016Co-Authors: Xueping Zhang, Steven Y. LiangAbstract:In the Machining process, cutting fluids are used with an objective to control Force and temperature thus promoting a longer tool life and better surface finish. However up until this point it has not been well understood how cutting fluid plays a part on the final workpiece residual stress, which is a key performance index in view of its bearing on fatigue life, corrosion resistance, and part geometry variations. This paper presents a quantitative sensitivity analysis of lubrication conditions in terms of cutting Force, cutting temperature, and residual stress based on the physics-based method. Results indicate that larger compressive residual stress can be obtained by increasing the flow rate of MQL. However, there is an optimal range of the flow rate to obtain maximal compressive residual stress within the test range. The proposed prediction model can carry a potential to be applied to dry, MQL, and flood cooling Machining.
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modeling the effects of minimum quantity lubrication on Machining Force temperature and residual stress
Machining Science and Technology, 2014Co-Authors: Xueping Zhang, Steven Y. LiangAbstract:□ Residual stress is one of the critical characteristics for assessing the qualities and functionalities of machined products in light of its direct effect on endurance limit, distortion, and corrosion resistance. Primary factors responsible for residual stresses distribution include mechanical effects, thermal effects, microstructure evolutions, and a combination of these mechanisms. This study investigates the effects of minimum quantity lubrication (MQL) on Machining Force, temperature and residual stress through a physics-based modeling method. Both the lubrication and cooling effects caused by MQL air-oil mixture contribute to changes in friction due to boundary lubrication as well as variations in the thermal stress due to heat loss. The modified Oxley's model is employed to predict the cutting Force and temperature directly from cutting conditions. The predicted cutting Force and temperature are then coupled into a thermal-mechanical model which incorporates the kinematic hardening and strain comp...
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The effects of minimum quantity lubrication (MQL) on Machining Force, temperature, and residual stress
International Journal of Precision Engineering and Manufacturing, 2014Co-Authors: Xia Ji, Beizhi Li, Xueping Zhang, Steven Y. LiangAbstract:Minimum quantity lubrication (MQL) Machining has achieved noticeable attention in both academic and industry research areas due to its minimum costs and maximum environmental protection. This paper focuses on the analysis of the effects of MQL parameters such as the flow rate of lubricant and the air-oil mixture ratio on cutting performances in terms of cutting Force, cutting temperature, and residual stress. Additionally, the cutting performances in MQL Machining are also compared with the dry and flood cooling Machining. The results show that the cutting fluid can considerably reduce the cutting Force and cutting temperature in Machining. For MQL Machining, there is a maximum effective flow rate of lubricant and it is influenced by the cutting speed. When the flow rate of lubricant is beyond the maximum effective value, the air-oil mixture ratio will no longer affect the cutting performances in Machining. This research can support the process planning in achieving the desired residual stress profile by strategically adjusting the MQL parameters.
Adriano Fagali De Souza - One of the best experts on this subject based on the ideXlab platform.
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Evaluating surface roughness, tool life, and Machining Force when milling free-form shapes on hardened AISI D6 steel
Reino Unido, 2020Co-Authors: Scandiffio Innocenzo, Diniz, Anselmo Eduardo, Adriano Fagali De SouzaAbstract:Today, the AISI D6 tool steel has been employed in the manufacture of dies and molds that require high mechanical properties. Such hard material is not trivial to Machining. Milling free-form geometries of D6 is a challenge usually faced at die and mold industries. Therefore, the current paper presents an investigation of free-form milling of hard material AISI D6 tool steel using a ball-end cemented carbide cutting tool. The influence of the toolpath direction (descendant and ascendant) and tool-workpiece surface contact were examined, and the Machining Forces, surface roughness, tool wear, and tool life were evaluated. The experiments were performed in two kinds of workpieces: in the first one, the milled surface was a cylindrical and in the second, the surface was inclined planes (with three different inclinations). The results indicate that the most influential factor for tool life was tool vibration. The higher the vibration, the shorter the tool life. Further, unlike milling of ordinary materials for molds and dies, the engagement of the center of the tool tip during cutting is advantageous for the Machining process of hard materials because it improves cutting stability, thus reducing surface roughness and increasing tool life829-1220752086FUNDAÇÃO DE AMPARO À PESQUISA DO ESTADO DE SÃO PAULO - FAPESPFUNDAÇÃO DE AMPARO À PESQUISA E INOVAÇÃO DO ESTADO DE SANTA CATARINA - FAPESCNão temNão te
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Influences of the tool path strategy on the Machining Force when milling free form geometries with a ball-end cutting tool
'Springer Science and Business Media LLC', 2020Co-Authors: Adriano Fagali De Souza, Diniz, Anselmo Eduardo, Berkenbrock Ernesto, Rodrigues, Alessandro RogerAbstract:Milling of free form geometries is an usual Machining operation in dies and moulds industry. A ball-end cutting tool is frequently used because its geometry allows the finishing and semi-finishing milling operations of any complex shape. However, unlike the ordinary milling Machining, the tool-surface contact alternates constantly what makes the process unstable. Due to the geometrical characteristics of this process, the value of the effective tool diameter depends on the depth of cut and the surface curvature, which alters the lead angle (angle formed between tool axis and surface normal direction). The effective tool diameter alternates constantly along the Machining. Moreover, it can be zero when the tool is using its centre to remove material, what makes the cutting speed null. A preview work has shown the severe alteration on the Cartesian components of the Machining Force when milling free form geometries. Such Force oscillation is still not predictable by the up methods, and its cutting phenomenon is still not clear. The current work aims to quantify the influences of the lead angle and the engagement of the tool tip centre into the cutting region, which may lead to improvements on the choice of milling strategy in Machining research and application. To do so, the Machining Force and its Cartesian components were investigated according to the process variables, such as: (1) tool path direction, (2) cutting way, (3) cutting speed, and (4) tool-surface contact (lead angle); when milling free form geometries with a ball-end cutting tool. Geometrical analyses together with milling experiments were carried out. The results show that the tool-surface contact had the greatest impact on the Forces, because it can either be related to the effective tool diameter or with the tool tip on the cutting zone. In this area, the material is removed part by shearing and part by ploughing (plastic deformation), which increases the Forces. The ascendant feed direction propitiates more stable process than its counterpart, and the cutting speed had also an influence on the Forces, regardless the contact between the tools with the machined surface37675687FUNDAÇÃO DE AMPARO À PESQUISA E INOVAÇÃO DO ESTADO DE SANTA CATARINA - FAPESC150174/2012-804/2011The authors thank CAPES for supporting this research project under the Grant PROENGENHARIAS PE 27/2008; CNPq for the postdoctoral scholarship 150174/2012-8-PDS; FAPESC under Project No. 04/2011 and the enterprises Villares Metals; VERO-SESCOI and CGTec
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The influence of tool-surface contact on tool life and surface roughness when milling free-form geometries in hardened steel
'Springer Science and Business Media LLC', 2020Co-Authors: Scandiffio Innocenzo, Diniz, Anselmo Eduardo, Adriano Fagali De SouzaAbstract:Machining process planning for milling hard materials with free-form surfaces using a ball nose end mill still requires empirical determination of the Machining parameters, which can limit the efficiency of the process, reduce tool life, and adversely affect workpiece surface quality. Milling free-form surfaces differs from ordinary milling because the tool-surface contact changes constantly, causing the cutting speed to vary from the programmed value (in regions where the tool touches the surface with its nominal diameter and the tool axis is parallel to the surface) to zero (in regions where the center of the tool tip cuts the material and the tool axis is almost perpendicular to the surface at the point of contact). This paper focuses on this issue and investigates the influence of effective cutting speed and tool-surface contact on tool wear and surface roughness. High-speed milling experiments were carried out in which convex circular surfaces of hardened D6 steel were machined with a ball nose end mill keeping the effective tool diameter along the tool’s circular trajectory constant in each experiment. The input variables were the lead angle (and consequently the effective tool diameter, which was kept constant in each experiment but varied from one experiment to another) and feed direction (ascendant and descendant). As the effective tool diameter increased from one experiment to another, the feed rate decreased. The results show, in contrast to other findings in the literature, that contact between the center of the tool tip and the workpiece can increase tool life and reduce roughness when milling free-form surfaces in hardened steels. Furthermore, Machining time is reduced as the smaller effective tool diameter leads to a higher feed rate. A relationship was also observed between the axial Machining Force and process stability when the tool tip is involved in the cutting process921-4615626FUNDAÇÃO DE AMPARO À PESQUISA DO ESTADO DE SÃO PAULO - FAPESP2013/00551-
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evaluating surface roughness tool life and Machining Force when milling free form shapes on hardened aisi d6 steel
The International Journal of Advanced Manufacturing Technology, 2016Co-Authors: Innocenzo Scandiffio, Anselmo Eduardo Diniz, Adriano Fagali De SouzaAbstract:Today, the AISI D6 tool steel has been employed in the manufacture of dies and molds that require high mechanical properties. Such hard material is not trivial to Machining. Milling free-form geometries of D6 is a challenge usually faced at die and mold industries. Therefore, the current paper presents an investigation of free-form milling of hard material AISI D6 tool steel using a ball-end cemented carbide cutting tool. The influence of the toolpath direction (descendant and ascendant) and tool-workpiece surface contact were examined, and the Machining Forces, surface roughness, tool wear, and tool life were evaluated. The experiments were performed in two kinds of workpieces: in the first one, the milled surface was a cylindrical and in the second, the surface was inclined planes (with three different inclinations). The results indicate that the most influential factor for tool life was tool vibration. The higher the vibration, the shorter the tool life. Further, unlike milling of ordinary materials for molds and dies, the engagement of the center of the tool tip during cutting is advantageous for the Machining process of hard materials because it improves cutting stability, thus reducing surface roughness and increasing tool life.
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influences of the tool path strategy on the Machining Force when milling free form geometries with a ball end cutting tool
Journal of The Brazilian Society of Mechanical Sciences and Engineering, 2015Co-Authors: Adriano Fagali De Souza, Anselmo Eduardo Diniz, Ernesto Berkenbrock, Alessandro Roger RodriguesAbstract:Milling of free form geometries is an usual Machining operation in dies and moulds industry. A ball-end cutting tool is frequently used because its geometry allows the finishing and semi-finishing milling operations of any complex shape. However, unlike the ordinary milling Machining, the tool-surface contact alternates constantly what makes the process unstable. Due to the geometrical characteristics of this process, the value of the effective tool diameter depends on the depth of cut and the surface curvature, which alters the lead angle (angle formed between tool axis and surface normal direction). The effective tool diameter alternates constantly along the Machining. Moreover, it can be zero when the tool is using its centre to remove material, what makes the cutting speed null. A preview work has shown the severe alteration on the Cartesian components of the Machining Force when milling free form geometries. Such Force oscillation is still not predictable by the up methods, and its cutting phenomenon is still not clear. The current work aims to quantify the influences of the lead angle and the engagement of the tool tip centre into the cutting region, which may lead to improvements on the choice of milling strategy in Machining research and application. To do so, the Machining Force and its Cartesian components were investigated according to the process variables, such as: (1) tool path direction, (2) cutting way, (3) cutting speed, and (4) tool-surface contact (lead angle); when milling free form geometries with a ball-end cutting tool. Geometrical analyses together with milling experiments were carried out. The results show that the tool-surface contact had the greatest impact on the Forces, because it can either be related to the effective tool diameter or with the tool tip on the cutting zone. In this area, the material is removed part by shearing and part by ploughing (plastic deformation), which increases the Forces. The ascendant feed direction propitiates more stable process than its counterpart, and the cutting speed had also an influence on the Forces, regardless the contact between the tools with the machined surface.
V N Gaitonde - One of the best experts on this subject based on the ideXlab platform.
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machinability investigations on hardened aisi 4340 steel using coated carbide insert
International Journal of Refractory Metals & Hard Materials, 2012Co-Authors: R Suresh, V N Gaitonde, S Basavarajappa, G L SamuelAbstract:Abstract The hard turning process with advanced cutting tool materials has several advantages over grinding such as short cycle time, process flexibility, compatible surface roughness, higher material removal rate and less environment problems without the use of cutting fluid. However, the main concerns of hard turning are the cost of expensive tool materials and the effect of the process on machinability characteristics. The poor selection of the process parameters may cause excessive tool wear and increased work surface roughness. Hence, there is a need to study the machinability aspects in high-hardened components. In this work, an attempt has been made to analyze the influence of cutting speed, feed rate, depth of cut and Machining time on machinability characteristics such as Machining Force, surface roughness and tool wear using response surface methodology (RSM) based second order mathematical models during turning of AISI 4340 high strength low alloy steel using coated carbide inserts. The experiments were planned as per full factorial design (FFD). From the parametric analysis, it is revealed that, the combination of low feed rate, low depth of cut and low Machining time with high cutting speed is beneficial for minimizing the Machining Force and surface roughness. On the other hand, the interaction plots suggest that employing lower cutting speed with lower feed rate can reduce tool wear. Chip morphology study indicates the formation of various types of chips operating under several cutting conditions.
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machinability analysis in turning tungsten copper composite for application in edm electrodes
International Journal of Refractory Metals & Hard Materials, 2010Co-Authors: V N Gaitonde, S. R. Karnik, M Faustino, Paulo J DavimAbstract:Abstract Electro-discharge Machining (EDM) is widely used in tooling industry, where it is applied on materials, which are too hard to be machined with conventional techniques. The tungsten–copper is broadly used as an EDM electrode for Machining of die steel and tungsten carbide workpieces. As, tungsten–copper electrode is more costly than conventional electrodes, there is a need to understand the machinability aspects in turning of this material. Hence, an attempt has been made in this paper to study the effects of cutting conditions on machinability characteristics such as cutting Force, feed Force, depth Force, Machining Force, power, specific cutting Force, arithmetic average surface roughness and maximum peak to valley height during tungsten–copper turning with K10 carbide cutting tool. The response surface methodology (RSM) based second order mathematical models of machinability aspects are developed using the data obtained through full factorial design (FFD). The adequacy of the machinability models is tested through the analysis of variance (ANOVA). The response surface analysis reveals that a combination of higher cutting speed with low-to-medium feed rate is advantageous in reducing the Forces, power and surface roughness, which in turn increases the specific cutting Force.
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analysis of machinability during hard turning of cold work tool steel type aisi d2
Materials and Manufacturing Processes, 2009Co-Authors: V N Gaitonde, S. R. Karnik, Luis Figueira, Paulo J DavimAbstract:Hard turning is an attractive replacement for grinding operations due to numerous advantages such as low capital investment, shorter setup time, higher material removal rate, better surface integrity, and elimination of cutting fluids. As a potential alternative process, there is a need to assess the machinability in high-precision and high-hardened components. The current study establishes the relationships between the cutting conditions (cutting speed, feed rate, and Machining time) on machinability aspects (Machining Force, power, specific cutting Force, surface roughness, and tool wear). The response surface methodology-based mathematical models are proposed for modeling and analyzing the effects of process parameters on machinability during turning of high chromium AISI D2 cold work tool steel using CC650WG wiper ceramic inserts. The experiments have been planned as per full factorial design. From the parametric analysis, it is revealed that the power increases with increase in feed rate, while the s...
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some studies in metal matrix composites Machining using response surface methodology
Journal of Reinforced Plastics and Composites, 2009Co-Authors: V N Gaitonde, S. R. Karnik, Paulo J DavimAbstract:The present study establishes the relationship between cutting conditions and machinability characteristics during the turning of metal matrix composites (MMC). The investigation aims at determining the effects of cutting speed and feed rate on Machining Force, cutting power, and specific cutting Force by developing second-order mathematical models using response surface methodology (RSM). Aluminum alloy reinForced with 20% of SiC particulates (A 356/20/SiCp-T6) were machined using a polycrystalline diamond (PCD) tool. The experiments have been planned as a full factorial design of experiments (FFD). The analysis of variance (ANOVA) was performed to check the adequacy of the mathematical models. The parametric analysis reveals that the Machining Force and cutting power increase with increase in feed rate while the specific cutting Force decreases.
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machinability investigations in hard turning of aisi d2 cold work tool steel with conventional and wiper ceramic inserts
International Journal of Refractory Metals & Hard Materials, 2009Co-Authors: V N Gaitonde, S. R. Karnik, Luis Figueira, Paulo J DavimAbstract:Hard turning with ceramic cutting tool has several benefits over grinding process such as elimination of coolant, reduced processing costs, improved material properties, reduced power consumption and increased productivity. Despite its significant advantages, hard turning can not replace all grinding due to lack of data concerning surface quality and tool wear and hence there is a need to study the machinability characteristics in high precision and high-hardened components. An attempt has been made in this paper to analyze the effects of depth of cut and Machining time on machinability aspects such as Machining Force, power, specific cutting Force, surface roughness and tool wear using second order mathematical models during turning of high chromium AISI D2 cold work tool steel with CC650, CC650WG and GC6050WH ceramic inserts. The experiments were planned as per full factorial design (FFD). From the parametric analysis, it is revealed that, the CC650WG wiper insert performs better with reference to surface roughness and tool wear, while the CC650 conventional insert is useful in reducing the Machining Force, power and specific cutting Force.
S. R. Karnik - One of the best experts on this subject based on the ideXlab platform.
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machinability analysis in turning tungsten copper composite for application in edm electrodes
International Journal of Refractory Metals & Hard Materials, 2010Co-Authors: V N Gaitonde, S. R. Karnik, M Faustino, Paulo J DavimAbstract:Abstract Electro-discharge Machining (EDM) is widely used in tooling industry, where it is applied on materials, which are too hard to be machined with conventional techniques. The tungsten–copper is broadly used as an EDM electrode for Machining of die steel and tungsten carbide workpieces. As, tungsten–copper electrode is more costly than conventional electrodes, there is a need to understand the machinability aspects in turning of this material. Hence, an attempt has been made in this paper to study the effects of cutting conditions on machinability characteristics such as cutting Force, feed Force, depth Force, Machining Force, power, specific cutting Force, arithmetic average surface roughness and maximum peak to valley height during tungsten–copper turning with K10 carbide cutting tool. The response surface methodology (RSM) based second order mathematical models of machinability aspects are developed using the data obtained through full factorial design (FFD). The adequacy of the machinability models is tested through the analysis of variance (ANOVA). The response surface analysis reveals that a combination of higher cutting speed with low-to-medium feed rate is advantageous in reducing the Forces, power and surface roughness, which in turn increases the specific cutting Force.
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analysis of machinability during hard turning of cold work tool steel type aisi d2
Materials and Manufacturing Processes, 2009Co-Authors: V N Gaitonde, S. R. Karnik, Luis Figueira, Paulo J DavimAbstract:Hard turning is an attractive replacement for grinding operations due to numerous advantages such as low capital investment, shorter setup time, higher material removal rate, better surface integrity, and elimination of cutting fluids. As a potential alternative process, there is a need to assess the machinability in high-precision and high-hardened components. The current study establishes the relationships between the cutting conditions (cutting speed, feed rate, and Machining time) on machinability aspects (Machining Force, power, specific cutting Force, surface roughness, and tool wear). The response surface methodology-based mathematical models are proposed for modeling and analyzing the effects of process parameters on machinability during turning of high chromium AISI D2 cold work tool steel using CC650WG wiper ceramic inserts. The experiments have been planned as per full factorial design. From the parametric analysis, it is revealed that the power increases with increase in feed rate, while the s...
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some studies in metal matrix composites Machining using response surface methodology
Journal of Reinforced Plastics and Composites, 2009Co-Authors: V N Gaitonde, S. R. Karnik, Paulo J DavimAbstract:The present study establishes the relationship between cutting conditions and machinability characteristics during the turning of metal matrix composites (MMC). The investigation aims at determining the effects of cutting speed and feed rate on Machining Force, cutting power, and specific cutting Force by developing second-order mathematical models using response surface methodology (RSM). Aluminum alloy reinForced with 20% of SiC particulates (A 356/20/SiCp-T6) were machined using a polycrystalline diamond (PCD) tool. The experiments have been planned as a full factorial design of experiments (FFD). The analysis of variance (ANOVA) was performed to check the adequacy of the mathematical models. The parametric analysis reveals that the Machining Force and cutting power increase with increase in feed rate while the specific cutting Force decreases.
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machinability investigations in hard turning of aisi d2 cold work tool steel with conventional and wiper ceramic inserts
International Journal of Refractory Metals & Hard Materials, 2009Co-Authors: V N Gaitonde, S. R. Karnik, Luis Figueira, Paulo J DavimAbstract:Hard turning with ceramic cutting tool has several benefits over grinding process such as elimination of coolant, reduced processing costs, improved material properties, reduced power consumption and increased productivity. Despite its significant advantages, hard turning can not replace all grinding due to lack of data concerning surface quality and tool wear and hence there is a need to study the machinability characteristics in high precision and high-hardened components. An attempt has been made in this paper to analyze the effects of depth of cut and Machining time on machinability aspects such as Machining Force, power, specific cutting Force, surface roughness and tool wear using second order mathematical models during turning of high chromium AISI D2 cold work tool steel with CC650, CC650WG and GC6050WH ceramic inserts. The experiments were planned as per full factorial design (FFD). From the parametric analysis, it is revealed that, the CC650WG wiper insert performs better with reference to surface roughness and tool wear, while the CC650 conventional insert is useful in reducing the Machining Force, power and specific cutting Force.
