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Abbas AT, Al Bahkali EA, Alqahtani SM, Abdelnasser E, Naeim N, Elkaseer A. Fundamental Investigation into Tool Wear and Surface Quality in High-Speed Machining of Ti6Al4V Alloy. MATERIALS 2021; 14:ma14237128. [PMID: 34885282 PMCID: PMC8658211 DOI: 10.3390/ma14237128] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/10/2021] [Revised: 11/17/2021] [Accepted: 11/18/2021] [Indexed: 11/16/2022]
Abstract
This paper reports a fundamental investigation consisting of systematic trials into the response of Ti6Al4V alloy to high-speed machining using carbide inserts. It is a useful extension to work previously published, and aims at assessing the impact of the process parameters, depth of cut, cutting speed and feed rate in addition to cutting length, and their interrelations, on observed crater and flank wear and roughness of the machined surface. The results showed that abrasion was the most important flank wear mechanism at high speed. It also showed that increased cutting length accelerated crater wear more than exhibited flank wear and had considerable effect on surface roughness. In particular, crater wear increased by over 150% (on average), and flank wear increased by 40% (on average) when increasing cutting length from 40 to 120 mm. However, cutting the same length increased surface roughness by 50%, which helps explain how progression of tool wear leads to deteriorated surface quality. ANOVA was used to perform statistical analyses of the measured data and revealed that cutting length and depth of cut had the greatest effect on both crater and flank wear of the cutting tool. These results confirm that high-speed machining of Ti6Al4V alloy is a reliable process, with cutting speed identified as having a relatively small influence on the tool wear and resultant roughness of the machined surface relative to other parameters.
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Affiliation(s)
- Adel T. Abbas
- Department of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia; (E.A.A.B.); (S.M.A.)
- Correspondence:
| | - Essam A. Al Bahkali
- Department of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia; (E.A.A.B.); (S.M.A.)
| | - Saeed M. Alqahtani
- Department of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia; (E.A.A.B.); (S.M.A.)
| | - Elshaimaa Abdelnasser
- Department of Production Engineering and Mechanical Design, Port Said University, Port Fuad 42526, Egypt; (E.A.); (N.N.); (A.E.)
| | - Noha Naeim
- Department of Production Engineering and Mechanical Design, Port Said University, Port Fuad 42526, Egypt; (E.A.); (N.N.); (A.E.)
| | - Ahmed Elkaseer
- Department of Production Engineering and Mechanical Design, Port Said University, Port Fuad 42526, Egypt; (E.A.); (N.N.); (A.E.)
- Institute for Automation and Applied Informatics, Karlsruhe Institute of Technology, 76344 Karlsruhe, Germany
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Analysis, modeling, and multi-objective optimization of machining Inconel 718 with nano-additives based minimum quantity coolant. Appl Soft Comput 2021. [DOI: 10.1016/j.asoc.2021.107416] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining. MATERIALS 2020; 13:ma13245677. [PMID: 33322699 PMCID: PMC7764427 DOI: 10.3390/ma13245677] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/11/2020] [Revised: 11/30/2020] [Accepted: 12/08/2020] [Indexed: 11/17/2022]
Abstract
This article presents the results of an experimental investigation into the machinability of Ti6Al4V alloy during hard turning, including both conventional and high-speed machining, using polycrystalline diamond (PCD) inserts. A central composite design of experiment procedure was followed to examine the effects of variable process parameters; feed rate, cutting speed and depth of cut (each at five levels) and their interaction effects on surface roughness and cutting temperature as process responses. The results revealed that cutting temperature increased with increasing cutting speed and decreasing feed rate in both conventional and high-speed machining. It was found that high-speed machining showed an average increase in cutting temperature of 65% compared with conventional machining. Nevertheless, high-speed machining showed better performance in terms of lower surface roughness despite using higher feed rates compared to conventional machining. High-speed machining of Ti6Al4V showed an improvement in surface roughness of 11% compared with conventional machining, with a 207% increase in metal removal rate (MRR) which offered the opportunity to increase productivity. Finally, an inverse relationship was verified between generated cutting temperature and surface roughness. This was attributed mainly to the high cutting temperature generated, softening, and decreasing strength of the material in the vicinity of the cutting zone which in turn enabled smoother machining and reduced surface roughness.
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Paschoalinoto NW, Batalha GF, Bordinassi EC, Ferrer JAG, Filho AFDL, Ribeiro GDLX, Cardoso C. MQL Strategies Applied in Ti-6Al-4V Alloy Milling-Comparative Analysis between Experimental Design and Artificial Neural Networks. MATERIALS 2020; 13:ma13173828. [PMID: 32872596 PMCID: PMC7504553 DOI: 10.3390/ma13173828] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/02/2020] [Revised: 08/20/2020] [Accepted: 08/26/2020] [Indexed: 01/14/2023]
Abstract
This paper presents a study of the Ti-6Al-4V alloy milling under different lubrication conditions, using the minimum quantity lubrication approach. The chosen material is widely used in the industry due to its properties, although they present difficulties in terms of their machinability. A minimum quantity lubrication (MQL) prototype valve was built for this purpose, and machining followed a previously defined experimental design with three lubrication strategies. Speed, feed rate, and the depth of cut were considered as independent variables. As design-dependent variables, cutting forces, torque, and roughness were considered. The desirability optimization function was used in order to obtain the best input data indications, in order to minimize cutting and roughness efforts. Supervised artificial neural networks of the multilayer perceptron type were created and tested, and their responses were compared statistically to the results of the factorial design. It was noted that the variables that most influenced the machining-dependent variables were the feed rate and the depth of cut. A lower roughness value was achieved with MQL only with the use of cutting fluid with graphite. Statistical analysis demonstrated that artificial neural network and the experimental design predict similar results.
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Affiliation(s)
- Nelson Wilson Paschoalinoto
- Faculty of Mechatronic Technology, National Service for Industrial Training (SENAI-SP), São Caetano do Sul, SP 09572-300, Brazil; (J.A.G.F.); (A.F.d.L.F.)
- Department of Mechatronics and Mechanical Systems Engineering, Polytechnic School of Engineering of the University of Sao Paulo (USP), São Paulo, SP 05508-900, Brazil;
- Department of Mechanical Engineering, University Center of the Mauá Institute of Technology (IMT), São Caetano do Sul, SP 09580-900, Brazil
- Technology Faculty of Mauá, The Paula Souza State Center for Technological Education (CEETEPS), São Paulo, SP 09390-120, Brazil
- Correspondence: (N.W.P.); or (E.C.B.); Tel.: +55-011-4239-3000 (N.W.P.)
| | - Gilmar Ferreira Batalha
- Department of Mechatronics and Mechanical Systems Engineering, Polytechnic School of Engineering of the University of Sao Paulo (USP), São Paulo, SP 05508-900, Brazil;
| | - Ed Claudio Bordinassi
- Department of Mechanical Engineering, University Center of the Mauá Institute of Technology (IMT), São Caetano do Sul, SP 09580-900, Brazil
- Department of Mechanical Engineering, University Center of Educational Foundation of Ignatius (FEI), São Bernardo do Campo, SP 09850-901, Brazil
- Correspondence: (N.W.P.); or (E.C.B.); Tel.: +55-011-4239-3000 (N.W.P.)
| | - Jorge Antonio Giles Ferrer
- Faculty of Mechatronic Technology, National Service for Industrial Training (SENAI-SP), São Caetano do Sul, SP 09572-300, Brazil; (J.A.G.F.); (A.F.d.L.F.)
| | - Aderval Ferreira de Lima Filho
- Faculty of Mechatronic Technology, National Service for Industrial Training (SENAI-SP), São Caetano do Sul, SP 09572-300, Brazil; (J.A.G.F.); (A.F.d.L.F.)
- Department of Mechanical Engineering, University of Taubaté (UNITAU), Taubaté, SP 12020-270, Brazil
| | - Gleicy de L. X. Ribeiro
- Institute for Innovation in Advanced Manufacturing and Microfabrication, National Service for Industrial Training (SENAI-SP), São Paulo, SP 04757-000, Brazil; (G.d.L.X.R.); (C.C.)
| | - Cristiano Cardoso
- Institute for Innovation in Advanced Manufacturing and Microfabrication, National Service for Industrial Training (SENAI-SP), São Paulo, SP 04757-000, Brazil; (G.d.L.X.R.); (C.C.)
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Dudzik K, Labuda W. The Possibility of Applying Acoustic Emission and Dynamometric Methods for Monitoring the Turning Process. MATERIALS 2020; 13:ma13132926. [PMID: 32629870 PMCID: PMC7372469 DOI: 10.3390/ma13132926] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/19/2020] [Revised: 06/26/2020] [Accepted: 06/27/2020] [Indexed: 11/16/2022]
Abstract
Ensuring optimal turning conditions has a huge impact on the quality and properties of the machined surface. The condition of the cutting tool is one of the factors to achieve this goal. In order to control its wear during the turning process, monitoring was used. In this study, the acoustic emission method and measure of cutting forces during turning were used for monitoring that process. The research was carried out on a universal lathe center (CU500MRD type) using a Kistler dynamometer with assembled removable insert CCET09T302R-MF by DIJET Industrial CO., LTD. A dynamometer allows to measure forces Fx (radial force), Fy (feed force) and Fz (cutting force). The turning process was performed on a shaft with 60 mm diameter made of 304L stainless steel. The AE research was carried at Physical Acoustics Corporation with the kit that includes: recorder USB AE Node, preamplifier, AE-sensor VS 150M and computer with dedicated software used for recording and analyzing AE data. The aim of this paper is to compare selected diagnostic methods: acoustic emission and cutting forces measurement for monitoring wear of cutting tool edge. Analysis of the research results showed that both selected methods of monitoring the turning process allowed the determination of the beginning of the tool damage process.
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Abbas AT, El Rayes MM, Luqman M, Naeim N, Hegab H, Elkaseer A. On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts. MATERIALS 2020; 13:ma13092036. [PMID: 32349405 PMCID: PMC7254342 DOI: 10.3390/ma13092036] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/03/2020] [Revised: 04/20/2020] [Accepted: 04/23/2020] [Indexed: 11/16/2022]
Abstract
This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.
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Affiliation(s)
- Adel T. Abbas
- Mechanical Engineering Department, College of Engineering, King Saud University, Riyadh 11421, P.O. Box 800, Saudi Arabia; (M.M.E.R.); (M.L.)
- Correspondence:
| | - Magdy M. El Rayes
- Mechanical Engineering Department, College of Engineering, King Saud University, Riyadh 11421, P.O. Box 800, Saudi Arabia; (M.M.E.R.); (M.L.)
| | - Monis Luqman
- Mechanical Engineering Department, College of Engineering, King Saud University, Riyadh 11421, P.O. Box 800, Saudi Arabia; (M.M.E.R.); (M.L.)
| | - Noha Naeim
- Department of Production Engineering and Mechanical Design, Port Said University, Port Fuad 42526, Egypt;
| | - Hussien Hegab
- Mechanical Design and Production Engineering Department, Cairo University, Giza 12613, Egypt;
| | - Ahmed Elkaseer
- Department of Production Engineering and Mechanical Design, Port Said University, Port Fuad 42526, Egypt;
- Institute for Automation and Applied Informatics, Karlsruhe Institute of Technology, 76344 Karlsruhe, Germany;
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