Carbon fiber reinforced polymeric (CFRP) composite materials are widely used in aerospace, automobile and biomedical industries due to their high strength to weight ratio, corrosion resistance and durability. High speed machining (HSM) of CFRP material is needed to study the impact of cutting parameters on cutting forces and chip microstructure which offer vital inputs to the machinability and deformation characteristics of the material. In this work, the orthogonal machining of CFRP was conducted by varying the cutting parameters such as cutting speed and feed rate at high cutting speed/feed rate ranges up to 346 m/min/ 0.446 mm/rev. The impact of the cutting parameters on cutting forces (principal cutting, feed and thrust forces) and chip microstructure were analyzed. A significant impact on thrust forces and chip segmentation pattern was seen at higher feed rates and low cutting speeds.
Titanium alloys are used as an aerospace material due to their inherent properties such as high strength to weight ratio, corrosion, and fracture resistance. However, the low conductivity and reactivity towards plastic deformation causes these materials to be difficult to cut category. The prediction of various parameters like chip formation and actual cutting forces are important factors for better machinability which involves lot of resources. To overcome such issues, this work proposes three-dimensional FE approach to simulate the machinability behavior of Ti-6Al-4V especially on conventional turning. The impact of cutting speed and feed rate on the cutting force, thrust force, feed force and surface roughness were analyzed experimentally for various conditions. The predicted machining forces showed strong correlation with the experimental results and the effective von mises stress were examined.
Inconel 718 is a nickel-based super alloy well suited for high-temperature applications encountered in space shuttles, aircraft black box and turbocharger due to their inherent properties. Taking into account of extreme working conditions, efficiency in the process of machining without affecting the nature of the surface integrity with utmost care assumes a lot of importance. In this current study, an attempt has been made to investigate the influence of cutting speed and feed rate on various machining aspects like cutting forces, chip morphology, surface roughness and tool wear during the orthogonal turning of Inconel 718. Also, the work has been focused on feed forces and thrust forces to understand the proper material deformation behaviour and surface integrity.
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