Machinability of Eco-Friendly Lead-Free Brass Alloys: Cutting-Force and Surface-Roughness Optimization

Toulfatzis, Anagnostis; Pantazopoulos, G.; David, Constantine; Sagris, Dimitrios; Paipetis, Alkiviadis S.

doi:10.3390/met8040250

Cited by 33 publications

(24 citation statements)

References 30 publications

(41 reference statements)

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“…More specifically, the selected cutting parameters (1750 rpm cutting speed, 2.0 mm depth of cut and 250 mm/min feed rate), contributed to the improvement of cutting force quality characteristic (from 446 to 431 N) for the CW511L brass alloy. The same machining parameters which were used for power consumption measurements (as received vs. heat-treated CW511L alloy) resulted in the improvement of cutting power, from 1600 W to 1420 W. The similar behaviour manifested by the two quality characteristics, i.e., power consumption and cutting force, could be also attributed to their common most influential machining parameter (depth of cut) [18]. Figure 6 and Table 8, show the surface roughness and topography results for the studied alloys.…”

Section: Cutting Forcesmentioning

confidence: 56%

“…Table 2. The "worst" combinations of cutting parameters for the quality characteristics (chip morphology, power consumption, cutting force, surface roughness-Ra) of studied lead-free brass alloys in "as received" condition [13,18]. …”

Section: Microstructure and Mechanical Propertiesmentioning

confidence: 99%

“…In previous works, machinability testing was performed in order to evaluate the chip morphology and power consumption, as well as the cutting force and the surface roughness [13,18]. In the previously mentioned studies, machining was conducted in lead-free brass alloys in the "as received" conditions and the optimum cutting parameters were defined by using Design of Experiments (DOE) statistical techniques.…”

Section: Machinability Evaluationmentioning

confidence: 99%

“…In previous research works, machinability tests were performed in turning operation in order to evaluate the chip morphology, the power consumption, the cutting force, and the surface roughness (Ra) of CW510L, CW511L, and C27450 lead-free brass alloys, in as-received condition [13,18]. Table 2 shows the combinations of cutting parameters which resulted in the worst result for each specific quality characteristic (chip morphology, power consumption, cutting force, and surface roughness) of the studied lead-free brass alloys, in the "as received" condition.…”

Section: Machinability Testingmentioning

confidence: 99%

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Final Heat Treatment as a Possible Solution for the Improvement of Machinability of Pb-Free Brass Alloys

Toulfatzis

Pantazopoulos²,

David

et al. 2018

Metals

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Abstract:Heat treatment was performed in order to improve the machinability of three lead-free extruded and drawn brasses, namely CuZn42 (CW510L), CuZn38As (CW511L), and CuZn36 (C27450), based on the concept of microstructural modification. The examined machinability criteria were the following: chip morphology, power consumption, cutting force, and surface roughness. All the above quality characteristics were studied in turning mode in "as received" and "heat treated" conditions for comparison purposes. The selected heat treatment conditions were set for CW510L (775 • C for 60 min), CW511L (850 • C for 120 min), and C27450 (850 • C for 120 min) lead-free brass alloys, according to standard specification and customer requirement criteria. The results are very promising concerning the chip breaking performance, since the heat treatment contributed to the drastic improvement of chip morphology for every studied lead-free brass. Regarding power consumption, heat treatment seems beneficial only for the CW511L brass, where a reduction by 180 W (from 1600 to 1420 W), in relation to the as-received condition, was achieved. Furthermore, heat treatment resulted in a marginal reduction by 10 N and 15 N in cutting forces for CW510L (from 540 to 530 N) and CW511L (from 446 to 431 N), respectively. Finally, surface roughness, expressed in terms of the average roughness value (Ra), seems that it is not affected by heat treatment, as it remains almost at the same order of magnitude. On the contrary, there is a significant improvement of maximum height (Rt) value of CW511L brass by 14.1 µm (from 40.1 to 26.0 µm), after heat treatment process performed at 850 • C for 120 min.

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Section: Cutting Forcesmentioning

confidence: 56%

Section: Microstructure and Mechanical Propertiesmentioning

confidence: 99%

Section: Machinability Evaluationmentioning

confidence: 99%

Section: Machinability Testingmentioning

confidence: 99%

See 2 more Smart Citations

Final Heat Treatment as a Possible Solution for the Improvement of Machinability of Pb-Free Brass Alloys

Toulfatzis

Pantazopoulos²,

David

et al. 2018

Metals

Self Cite

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show abstract

“…Such studies were mainly focused in the optimization of various machining criteria under certain machining process parameters variation, using parametric and non-parametric studies, e.g., design of experiments (DOE) and analysis of variance (ANOVA) approaches (see relevant Ref. [9][10][11]).…”

Section: Introductionmentioning

confidence: 99%

A Comprehensive CFD Model for Dual-Phase Brass Indirect Extrusion Based on Constitutive Laws: Assessment of Hot-Zone Formation and Failure Prognosis

Pashos¹,

Pantazopoulos²,

Contopoulos³

2018

Metals

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A numerical method for the precise calculation of temperature, velocity and pressure profiles of the α-β brass indirect hot extrusion process is presented. The method solves the Navier-Stokes equations for non-Newtonian liquids with strain-rate and temperature-dependent viscosity that is formulated using established constitutive laws based on the Zener-Hollomon type equation for plastic flow stress. The method can be implemented with standard computational fluid dynamics (CFD) software, has relatively low computational cost, and avoids the numerical artifacts associated with other methods commonly used for such processes. A response surface technique is also implemented, and it is thus possible to build a reduced order model that approximately maps the process with respect to all combinations of its parameters, including the extrusion speed and brass phase constitution. The reduced order model can be a very useful tool for production, because it instantaneously provides important quantities, such as the average pressure or the temperature of hot-spots that are formed due to the combined effect of die/billet friction and the generation of heat from plastic deformation (adiabatic shear deformation heating). This approach can assist in the preliminary evaluation of the metal flow pattern, and in the prediction and prevention of critical extrusion failures, thus leading to subsequent process and product quality improvements.

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Cutting Forces in Machining of Low-Lead and Lead-Free Brass Alloys

Müller

Sørby

2022

Lecture Notes in Electrical Engineering

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Machinability of Eco-Friendly Lead-Free Brass Alloys: Cutting-Force and Surface-Roughness Optimization

Cited by 33 publications

References 30 publications

Final Heat Treatment as a Possible Solution for the Improvement of Machinability of Pb-Free Brass Alloys

Final Heat Treatment as a Possible Solution for the Improvement of Machinability of Pb-Free Brass Alloys

A Comprehensive CFD Model for Dual-Phase Brass Indirect Extrusion Based on Constitutive Laws: Assessment of Hot-Zone Formation and Failure Prognosis

Cutting Forces in Machining of Low-Lead and Lead-Free Brass Alloys

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