Influence of cutting parameters on cutting forces and surface roughness in dry turning of Al using PCD and different coated tools

Kumar, Rakesh; Pattnaik, Sisira Kanta; Minz, J K; Padhi, Sachidananda; Sarangi, Sunil

doi:10.1007/s12046-019-1155-4

Cited by 9 publications

(7 citation statements)

References 36 publications

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“…Beyond the factors mentioned, the temperature at the cutting interface, lubrication, and cooling systems also play a role in determining optimal cutting parameters. Achieving a balance between high reinforcement speed and feed rate, without compromising surface finish and tool longevity, is a delicate task that demands careful calibration [27] underscores the importance of understanding and adapting to the mechanical properties of the reinforcement materials, as their hardness and abrasiveness can have a significant impact on tool wear. To minimize tool wear and enhance the overall machining process, operators should continuously monitor and fine-tune the cutting parameters based on real-time performance data [7].…”

Section: Resultsmentioning

confidence: 99%

“…The cutting speed (Vc) was varied between 300 m min −1 and 700 m min −1 , and the feed rate (f) was varied between 0.045, 0.06, 0.09, and 0.125 mm rev −1 at a constant depth of cut of 0.2 mm. The PCD tool outperformed all others in terms of performance, but interestingly, the WC tool offered a better surface polish with less tool wear [27]. In this study, an effort has been made to simulate the evaluation of machinability using the response surface methodology in the machining of homogenized 20% SiCp LM25 Al MMC produced using the stir cast process.…”

Section: Introductionmentioning

confidence: 99%

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Investigation on the machinability of Biochar reinforced AA5083 Metal Matrix composites fabricated by stir casting technique

Praveen,

Raja,

Jannet

et al. 2023

Eng. Res. Express

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Over the past two decades, there has been a significant rise in the demand for Aluminum Metal Matrix Composites (AAMCs) due to their notable advantages such as lightweight properties, increased strength, and enhanced hardness. In this study, three distinct AAMC samples based on Al5083 alloy, each varying in reinforcement levels at 4%, 8%, and 12% by weight were used. These composites were produced through a stir-casting process. The biochar used in our research was obtained through a pyrolysis process, adding an environmentally friendly and sustainable aspect to the composite materials. In the machining aspect of the study, A systematic L27 Taguchi Design of Experiment approach was used to investigate the influence of input parameters, namely cutting speed, feed rate, depth of cut, and weight percentage of reinforcement material, on the machining process. Further regression models were developed to gain insights into the relationships between these parameters and the resulting surface roughness. Turning operations at a cutting speed of 1050 rpm, a feed rate of 60 mm, and a depth of cut of 0.75 mm were idle for superior surface roughness and to assess the impact of the reinforcement material on the machined surface.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Investigation on the machinability of Biochar reinforced AA5083 Metal Matrix composites fabricated by stir casting technique

Praveen,

Raja,

Jannet

et al. 2023

Eng. Res. Express

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“…PCD tool shows promising results than other tools in machining of aluminium under dry conditions except surface finish. WC tool enhanced surface finish than other tools [78].…”

Section: Dry Machiningmentioning

confidence: 95%

A review on cutting fluids used in machining processes

Singh

Gill²,

Dogra³

et al. 2021

Eng. Res. Express

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Cutting fluids provide cooling at the cutting tool and on the surface of work piece, lubricate the tool-workpiece interface and evacuate chips from the cutting zone in the machining processes. The primary reason for using cutting fluid is to reduce the temperature at cutting zone and friction wear either through cooling or lubrication. To maximize the efficiency of cutting fluids in machining processes the knowledge of machining conditions and cutting fluid types are critically important. However, misemploy of the cutting fluid and non efficient method of disposal can raise health issues and environmental impact. In this paper, an attempt has been made to provide overview of cutting fluids type, cooling techniques and main alternatives as dry machining, cryogenic cooling, minimum quantity lubrication and hybrid cooling minimizing use of cutting fluids. The inclusion of solid lubricants, nano fluids in lubrication/cooling techniques results in increase in the productivity of the process due to reduction in friction and heat at the cutting zone. The cutting parameters and type of tools utilized by various researchers have been summed up and introduced in this paper to provide useful information to various researcher works.

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“…It is depicted that due to excellent heat conductivity and hot hardness, poly crystalline diamond outperforms cubic boron nitride, coated carbide, and uncoated carbide. As a result, the poly crystalline diamond tool produces superior surface finish and wear resistance [39,40]. The influence of two different types of cutting tools, carbide and poly crystalline diamond, on machined surface roughness and flank wear during machining Al7075 composites was explored.…”

Section: Introductionmentioning

confidence: 99%

Machinability study of silicon carbide and cenosphere reinforced Al7075 composite using three different tool materials

Setia,

Chahuan

2023

Materialwissenschaft Werkst

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This research conducted a machinability study on Al7075 composite reinforced with nano‐sized (100 nm) silicon carbide and cenosphere (industrial waste) particulates with 1.8 % weight. These composites were fabricated utilizing an ultrasonically assisted stir‐casting setup and scanning electron microscope investigation was conducted to evaluate the dispersion properties of the reinforcement in the matrix phase. During the study, the effect of variation of feed rate, cutting speed and depth of cut on cutting forces and tool tip temperature has been studied. A total of 253 experiments were conducted using three different tool inserts polycrystalline diamond, cermet, and coated carbide under dry cutting conditions. Among the two components of the cutting force, it was noted that the primary cutting force was the largest. A full factorial response surface regression model has been developed and it is found that the regression model can predict cutting force and temperature with fair accuracy.

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Influence of cutting parameters on cutting forces and surface roughness in dry turning of Al using PCD and different coated tools

Cited by 9 publications

References 36 publications

Investigation on the machinability of Biochar reinforced AA5083 Metal Matrix composites fabricated by stir casting technique

Investigation on the machinability of Biochar reinforced AA5083 Metal Matrix composites fabricated by stir casting technique

A review on cutting fluids used in machining processes

Machinability study of silicon carbide and cenosphere reinforced Al7075 composite using three different tool materials

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