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Review of Boring Process Parameter for Geometric Dimension & Tolerances
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High precision rotary shafts with precise geometrical tolerances are generally mounted with a micron level clearance between the gears and casing during operation in industrial applications. Dynamics cyclic loads are inevitable in most of these applications which has an adverse effect on the fatigue life of the critical parts. Ensuring close dimensional tolerances and coaxiality during machining is highly desirable, as it affects the rotary characteristics in many applications. Thus, control of coaxiality error plays a vital role in rotating shafts and high precision machine tools. However, use of high precision machining would drastically increase the cost of manufacturing. Thus, a cost-effective machining process that could potentially reduce the coaxiality error is of high industrial importance. The present research efforts made an attempt to achieve minimum coaxi-ality error on cylindrical machined parts by optimizing parameters (cutting speed, feed rate, depth of cut and cutting tool nose radius). Experiments are planned, viz. central composite design matrix and statistical analysis determine the influence of machine parameters on coaxiality error of high-strength Al 7075 alloy by applying response surface methodology. Feed rate and depth of cut factors showed significant effect on coaxiality error. All machining parameters showed a non-linear effect on coaxiality error, which defines the strong interaction factor effects. The empirical equations derived were used to minimize coaxiality error by determining a set of machining parameters, viz. applying Big-Bang and Big Crunch and Rao (Rao-1, Rao-2 and Rao-3) algorithms. Rao algorithms outperform the Big-Bang and Big Crunch algorithm both in computation effort and solution accuracy. The results of Rao algorithms are experimentally verified, which resulted in reduced coaxiality error equal to 1.013 µm and resulted in 72.6% improvement compared to CCD experiments.
Fibre metal laminates (FMLs) are multilayered metal composite materials currently used in aeronautical structures, especially where fatigue and impact resistance are required. FMLs are produced in large panels and often require assembly using the drilling process for riveting purposes. Hole making is a critical machining process in the joining and assembly of aeronautical components, which has to meet stringent tolerance requirements. This paper reports a systematic analysis of hole integrity when drilling an FML known as GLARE®. In particular, the primary objective is to investigate the impact of three different drill coatings (TiAlN, TiN and AlTiN/TiAlN), against several important hole parameters: thrust force, hole size, circularity, cylindricity and perpendicularity. The results show that TiAlN-coated drills produced the highest thrust force, while TiN-coated drills produced holes with the lowest deviation between the hole diameter measured at the entry and the exit and that the drill coating was the most influential parameter for the resulting hole size. TiAlN-coated drills resulted in the highest circularity at the upper part of the hole, while hole cylindricity tended to be best when using AlTiN/TiAlN- and TiN-coated drills. The ANOVA analysis shows that the drill coating and the spindle speed had a significant influence on hole size and circularity, while drill coating was the only influential parameter on hole cylindricity, and spindle speed was the only contributing parameter on hole perpendicularity. Finally, scanning electron microscopy analyses showed two distinct hole wall surface damage phenomenon due to broken fibres and evacuated metallic chips.
This paper presents the outcome of a study on the effect of the machining conditions on some performance parameters during dry and hard boring of ASTM A304 low alloy steel round bar with tungsten-carbide insert using a 3-level factorial design of experiment-based response surface methodology. It involved modelling, prediction and optimisation of the performance parameters subject to constraints on variation of the machining conditions. Within the limits defined by levels of the machining, the performance parameters were randomly determined in 27 runs of boring experiments. These experiments, which were performed on a D360 x 1000HS excel lathe machine, serial no J320581, involved dry and hard boring of 27 ASTM A304 low alloy steel specimen work-pieces using tungsten-carbide inserts at different levels of low, medium and high as specified for the machining conditions. The data analysis was performed using Design Expert software version 9.0.6.2 to model, predict, and to obtain the optimal machining conditions, and the corresponding performance parameters. The study revealed the control factors to have varying effects on the response variables of which the prime factor is the cutting speed, for the tool wear and cutting temperature, and depth of cut, for the material removal rate. Hence, it is recommended that the obtained values of these factors should be adopted for optimal machining of the aforementioned material.
The statistical mathematical models are developed to investigate the influence of cutting parameters on surface roughness, tool wear, cutting force, tangential force and the work piece vibration in boring of AISI 4340 steels. A full factorial design of experiments is used to conduct 27 experiments on AISI 4340 as the work piece material and TiCN–Al2O3–TiN multi-layered coated carbide inserts. Online data acquisition of cutting forces on the cutting tool and the work piece vibrations are measured by using piezo-electric dynamometer and laser Doppler vibrometer, respectively. This paper proposes optimization method using grey relational analysis (GRA) and predictive models like support vector machine and response surface method are used to predict the GRG values and optimize the machining parameters. The GRA is used for converting multi response optimization problem into optimization of single objective of grey relational grade (GRG). Finally confirmation test was performed and also optimized the machining parameters to minimize the surface roughness (Ra), tool wear (VB), cutting force (Fx), tangential force (Fz) and work piece vibration (VA).
Reportedly, the drill geometry influences the drilling operation. In fact, the performance of drill bit is strongly associated with productivity thus with economy of production. Moreover, the typical performance indicators i.e. deviation from diameter, cylindricity, perpendicularity and concentricity are altered by drill geometry. This fact urges for novel design of drills with further optimization of performance indicators of hole-quality. In that perspective, herein, new drill geometries were designed and fabricated. Afterward, those drills were employed to create holes on AISI 4140 steel and their performances were investigated and optimized to suggest cutting parameters of best interest. For performance tests, four different drill geometries, four different cutting speeds (90, 100, 110, 120 m / min) and four different feeds (0.15, 0.20, 0.25, 0.30 mm/rev) were practiced. To measure the performance of the drills, the quality of drilled holes was studied in terms of the deviation from diameter, cylindricity, perpendicularity and concentricity. During experiment the Geometry 3 that was developed as original drill geometry exhibited poor chip evacuation. As such, Geometry 4 was developed by considering these negativities; and it was found to demonstrate superior performance compared to other geometries in terms of hole-quality. Furthermore, ANOVA revealed that the drill bit flute geometry is the most influential factor. Lastly, the Taguchi S/N approach disclosed that drilling with Geometry 4 at cutting speed of 90 m/min and feed rate of 0.15 mm/rev produced optimum machining performance.
In this paper, statistical models were developed to investigate effect of cutting parameters on surface roughness and root mean square of work piece vibration in boring of stainless steel. A mixed level design of experiments was prepared with process variables of nose radius, cutting speed and feed rate. According to design of experiments, eighteen experiments were conducted on AISI 316 stainless steel with PVD coated carbide tools. Surface roughness, tool wear and vibration of work piece were measured in each experiment. A laser Doppler vibrometer was used to measure vibration of work piece in the form of acousto optic emission signals. These signals were processed and transformed in to different frequency zones using a fast Fourier transformer. Analysis of variance was used to identify significant cutting parameters on surface roughness and root mean square of work piece vibration. Predictive models like response surface methodology, artificial neural network and support vector machine were used to predict the surface roughness and root mean square of work piece vibration. Cutting parameters were optimized for minimum surface roughness and root mean square of work piece vibration using a multi response optimization technique.
Microalloyed high carbon steels (such as C70S6, SMA40 and FRACTIM) have been
considered to be economic alternatives to powder metal and conventional steel, having been
used as main crackable con-rod materials in recent years. Compared with powder metal and
conventional steel, these microalloyed high carbon steels have remarkable advantages. One of
the main advantages is that cost reduction can be achieved by changing the micro-structure of
the con-rod. Sawing and machining processes of the rod and cap, in order to mate two faces
can be eliminated, and is believed to reduce the production cost by 25%. Another advantage
of this production method is that fracture-splitting connecting rods exhibit 30% higher fatigue
strength and 13% less weight than conventional connecting rods, and can be splitted into two
pieces (big body and cap) by fracturing with an instant impact load. Compared with powder
metal and cast con-rods, it also has lower cost for the whole manufacturing process. Hence, it
provides more advantageous production opportunities, and is prefered in manufacturing
technology mostly. In this article, the metallographic and fracture surface analysis have been
investigated using optical and SEM method. Hardness of C70 steel is also determined. In the
article it has been made clear that, the microstructure of the fracture-split con-rod has a fine
grain size with densely pearlite because of its high carbon content. Also it is shown that a
high hardness value is determined approximately 280-300 HB. Almost no deformation
exhibits after splitting into 2 pieces, which is what any con-rod productor would like to expect
when utilizing C70S6 crackable steel in production phase.
In this study, the effects of cutting parameters, boring tool material and the overhang ratio of boring tool (tool clamping length) on the deviation from circularity of bored hole were examined experimentally. The optimal cutting condition can be estimated by the analysis of the signal to noise (S/N) ratio in Taguchi method. The individual contributions of each factor on the deviation from circularity were calculated by using the Analysis of Variance (ANOVA). Therefore, at the determined condition, it could be observed that whether if a factor is significant or not. Also it was observed that the values of deviation from circularity increased significantly with increasing the effective tool length at the lower depth of cut values. Besides, the circularity could be improved with increasing the depth of cut values for the same tool clamping lengths.
In this paper the drilling of mild steel with the help of CNC drilling machining operation with tool use high speed steel by applying taguchi methodology has been reported. The signal-to-noise ratio applied to find optimum process parameter for CNC drilling machining .A L9 orthogonal array and analysis of variance(ANOVA) are applied to study the performance characteristics of machining parameter (spindle speed, feed, depth) with consideration of good surface finish as well as high material removal rate(MRR) .Surfacefinishing is one of the prime requirements of customers of machining parts .Results obtained by taguchi method and signal-to-noise ratio match closely with (ANOVA) and the feed is most effective factor for MRR. And spindle speed is the most effective factor for surface roughness. Multiple regression equation are formulated forestimating predicted value surface roughness and material removal rate
a b s t r a c t In this work, effect of machining parameters cutting speed, feed rate and depth of cut, geometrical parameters cutting insert shape, relief angle and nose radius were investigated and optimized using Taguchi based grey relational analysis. 18 ISO designated uncoated cemented carbide inserts of different geometries were used to turn practically used auto-motive axles to study the influence of variation in carbide inserts geometry. Performance measures viz., flank wear, surface roughness and material removal rate (MRR) were optimized using grey relational grade, based on the experiments designed using Taguchi's Design of Experiments (DoE). A weighted grey relational grade is calculated to minimize flank wear and surface roughness and to maximize MRR. Analysis of variance shows that cutting insert shape is the prominent parameter followed by feed rate and depth of cut that contributes towards output responses. An experiment conducted with identified optimum condition shows a lower flank wear and surface roughness with higher MRR. The confirma-tion results obtained are confirmed by calculating confidence interval, which lies within the width of the interval.
Design of experiments has been used to study the effect of the main turning parameters such as feed rate, tool nose radius, cutting speed and depth of cut on the surface roughness of AISI 410 steel. A mathematical prediction model of the surface roughness has been developed in terms of above parameters. The effect of these parameters on the surface roughness has been investigated by using Response Surface Methodology (RSM). Response surface contours were constructed for determining the optimum conditions for a required surface roughness. The developed prediction equation shows that the feed rate is the main factor followed by tool nose radius influences the surface roughness. The surface roughness was found to increase with the increase in the feed and it decreased with increase in the tool nose radius. The verification experiment is carried out to check the validity of the developed model that predicted surface roughness within 6% error.
The effects of cutting speed and cutting tool geometry on cutting forces are investigated in this study. For this purpose, nickel-base super alloy, Inconel 718, is machined with dry cutting conditions by using digital controlled computer lathe with ceramic cutting tools in two different geometries and three different material qualities. Metal removing process is carried out for four different cutting speeds (150m/min, 200m/min, 250m/min, and 300m/min), while a cutting depth of 2mm and a feed rate of 0.20mm/rev are kept constant. As a result of the experiments, the lowest main cutting force, which depends on tool geometry, is obtained as 672N with KYON 2100 SNGN 120712 ceramic tool and the maximum cutting force is determined as 1346N with the ceramic cutting tool having KYON 4300 RNGN 120700 geometry. Depending on the cutting speed, the lowest main cutting force is recorded as 812N at 250m/min while the highest main cutting force is recorded as 955N at 150m/min. Plastic deformation, flank edge wear, notch and build-up edge are determined in high cutting speeds.
In this study, the effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI H13 steel were experimentally investigated. Cubic boron nitrite inserts with two distinct edge preparations and through-hardened AISI H13 steel bars were used. Four-factor (hardness, edge geometry, feed rate and cutting speed) two-level fractional experiments were conducted and statistical analysis of variance was performed. During hard turning experiments, three components of tool forces and roughness of the machined surface were measured. This study shows that the effects of workpiece hardness, cutting edge geometry, feed rate and cutting speed on surface roughness are statistically significant. The effects of two-factor interactions of the edge geometry and the workpiece hardness, the edge geometry and the feed rate, and the cutting speed and feed rate also appeared to be important. Especially honed edge geometry and lower workpiece surface hardness resulted in better surface roughness. Cutting-edge geometry, workpiece hardness and cutting speed are found to be affecting force components. The lower workpiece surface hardness and honed edge geometry resulted in lower tangential and radial forces.
In this article, mechanics of boring process on cast iron automotive engine cylinders is explored experimentally. In order
to shorten the boring cycle time and to improve quality of the cylinder holes, effects of various cutting conditions as spindle
speed, feedrate, inserts, and coatings are investigated. Real-time cutting forces are measured with dynamometer during the
process. Surface roughness on the engine cylinders, flank, and crater tool wears are measured and compared in various cutting
conditions. It is concluded that by selecting proper cutting conditions, cutting forces can be controlled below a threshold
value, cycle time can be shortened, tool life and part quality can be increased; therefore, the cost of automotive engine
boring process can be reduced significantly.
KeywordsEngine-Boring-Force-Cycle time-Feedrate-Wear
Development in the field of materials brings numerous newer grades, but the machinability studies over those materials have to be done. Drilling is the major manufacturing process which covers around 25% of machining processes. Magnesium AZ31 is considered for the present investigation to perform the drilling operation. Control over the responses like circularity, perpendicularity and cylindricity will improve the life of fastening element due the reduction of compressive and shear stress. The deviation of above responses will increase compressive and shear stress leads to fatigue and also increases the assembling time. This work concentrates on the reduction of such distinctive properties. Empirical model was developed to find the responses for the usage of process planning engineer, later optimization carried out through Desirability Function Approach (DFA). The multi objective optimization suggesting the spindle speed of 1100.02 rpm, the feed rate of 0.038 mm/rev. and the drill diameter of 6 mm for minimizing all the responses considered. Similarly Grey Relational Analysis (GRA) applied to reduce the responses. Evaluation made between DFA and GRA which highlights the superiority of GRA for circularity and cylindricity. The DFA be the superior technique for minimizing the perpendicularity.
Cutting parameters have a significant influence on the surface finish after turning, which can generate unwanted surface roughness. Thus, the parameters optimization could be a favorable strategy to improve the machined part quality. Therefore, the optimization of the cutting speed (vc), feed rate (f) and depth of cut (ap) on finish turning of 6082-T6 aluminum alloy using an uncoated carbide tool (positive rake angles and 0.4 mm tip radius) under dry and reduced quantity lubricant (RQL) conditions was performed. The input variables were combined and randomized via Box–Behnken design of experiments. The surface roughness profiles were recorded, and the roughness parameters Ra and Rz were measured in each combination of parameters. After optimization, the best results of Ra (0.44 μm) and Rz (2.73 μm) after dry machining were obtained with vc = 851 m/min, f = 0.07 mm/rev. and ap = 2 mm. Since RQL machining, the correspondent levels (vc = 403 m/min, f = 0.05 mm/rev., ap = 0.5 mm) resulted in the lowest values of Ra (0.18 μm) and Rz (0.96 μm). The RQL favored the chip formation in turning of AA6082-T6, minimized the occurrence of grooves (scratches), burrs and waviness on the machined surface and generated better surface quality.
Manufacturing is always the heart of majority of industries. Drilling is an extremely important and an essential machining process which requires a lot of attention as in most of the cases it is required for assembly purposes. Majority of the holes produced during drilling are made with the help of Vertical Machining Centre (VMC) meant for pin- hole assembly. Though the tolerance is within limit, assembly problems arise due to the improper geometry of these holes. Various geometrical tolerances like cylindricity, circularity, perpendicularity and position errors are responsible for such assembly problems. This investigation is focussed on cylindricity and perpendicularity in the drilling of Wrought Cast Steel Grade B (WCB) material using SOMX 050204 DT insert. In this work, effect of machining variables like cutting speed, feed rate and depth of cut (canned cycle) are investigated and optimized using grey relational analysis (GRA). Reliable experiments are conducted based on a 33 full factorial, replicated twice. Second order regression models are developed for predicting cylindricity and perpendicularity. The models’ adequacy has been checked by calculating correlation coefficient. It shows that the developed models are well fitted for the prediction of responses within the specific range of input variables.
The dominance of the spark eroding process in complex ceramic components has promoted a significant growth analysis in the ceramic composites domain in modern manufacturing industries. The latest developments in ceramic components are concentrated on both the enhancement of the mechanical properties and the machinability of complex 3D parts while using spark EDM. The current (I), pulse on time (Ton), pulse off time (Toff), and dielectric flushing pressure (DP) are considered sparking parameters for the machining of a Si3N4–TiN ceramic composite. These composites find their application in high-temperature environments, viz. metal forming, extrusion dies, turbine blade, and non-ferrous molten metal handling components. Taguchi's orthogonal array (OA), L18, has been used to design the experiments. The optimal machining inputs are determined by the grey relational grade (GRG), which is attained from the grey relation analysis (GRA) for various response characteristics, such as the material removal rate (MRR), tool wear rate (TWR), circularity (CIR), cylindricity (CYL), and perpendicularity (PER). The significant parameters are identified via an analysis of variance (ANOVA). Finally, the optimized process parameters resulting in a higher MRR, lower TWR, lower form tolerance, and decreased orientation tolerance are verified through a confirmation test demonstrating that sparking process responses can be effectively improved. 2016
In this article, effect of cutting parameters, namely, cutting speed, feed rate and tool nose radius, on the tool life was examined experimentally. The experiments were performed on boring of AISI 316 steel with cemented carbide tool inserts. Design of experiments was prepared, and eight experiments were performed with two levels of the cutting parameters. The effects of cutting parameters were analyzed by evaluating the amplitude of workpiece vibration, surface roughness and volume of metal removed. The experimental data were taken for evaluation of tool life for a flank wear of 0.6 mm in all the eight trials. A laser Doppler vibrometer was used for online data acquisition of workpiece vibration, and a high-speed fast Fourier transform analyzer was used to process the acousto-optic emission signals for the workpiece vibration. Taguchi, analysis of variance and regression analysis methods were used to identify significant cutting parameters affecting the workpiece vibrations, surface roughness and volume of metal removed. All selected analysis methods used in this study predicted similar cutting parameter.
This study deals with the development of displacement of the tool (amplitude of vibration), cutting temperature and tool wear prediction model for boring process using artificial neural networks (ANNs). The experiments have been conducted using full factorial design on an all-geared head lathes with the experimental setup. The adequacy of the developed model is verified by using the neural network model, which has been developed using the feed-forward back propagation algorithm using training data and tested using test data. To judge the ability of the model to predict displacement of the tool (amplitude of vibration), cutting temperature and tool wear values, the percentage deviation and average absolute percentage deviation have been used. The predicted ANN model values are very close to the experimental results.
This article presents an experimental work and investigation on electrical discharge machining (EDM) of Inconel 718 and 625 superalloys. These superalloys are used for making parts like turbine blades, marine components, and nuclear reactor components. The precise components made up of superalloys which have cylindrical, square, and hexagonal machined features are required regular estimations of cylindricity, circularity, perpendicularity, and parallelism. In this work, EDM of the above said superalloys was carried out and form tolerances were analyzed. The significance of input parameters namely peak current, pulse-on time (T on), and pulse-off time (T off) on the form tolerances were investigated. In addition to these, the influence of individual parameters were also analyzed by analysis of variance (ANOVA) technique.
This paper is focused on the optimal selection of the parameters of a
passive dynamic vibration absorber (DVA) attached to a boring bar. The
boring bar was modeled as an Euler-Bernoulli cantilever beam and
the stability of the system was analyzed in terms of the bar and the
absorber characteristics. To obtain the optimum parameters of the
absorber, a classical method for unconstrained optimization problems has
been used. The selection criterion consisted of the maximization of the
minimum values of the stability lobe diagram. Empirically fitted
expressions for the frequency and damping ratio of the DVA (which permit
to obtain its stiffness and damping) are proposed. These expressions are
fully applicable when the damping ratio of the boring bar is non-null as
it is in practical operations. The computed results show a clear
improvement in the stability performance regarding other methodologies
previously used.
In this paper, vibration cutting (VC) has been applied to boring and drilling processes using a vibration device we developed. We analyzed the effect of vibration in boring by investigating the surface roughness of workpiece with the help of Taguchi method and analysis of variance (ANOVA). It has been shown that the utilization of VC in boring improves the surface roughness prominently. The shading-area method we proposed can be employed as a simple and feasible approach for the analysis of burrs in intersecting holes. High-frequency vibration boring can reduce the burr formation in intersecting holes effectively. The experimental results show that the utilization of VC reduces the burrs in intersecting holes noticeably.
Optimization of Process Parameters of Friction Stirs Welding of Aluminum Alloys (6061) Using Taguchi Method
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Available: https://objects.scraper.bibcitation.com/userpdfs/2023-04-27/4fd7febc-f6fd-44fa-b97a-55c74b849485.pdf