Browse Topic: Turning

Items (44)

A Machine learning Approach for the prediction of Surface Roughness Using The Tool Vibration Data In Turning Operation

2025-28-0152To be published on 02/07/2025

Surface roughness is a key factor in different machining processes and plays an important role in ergonomics, assembly, wear and fatigue life of components. Functionality, performance and durability of parts are also affected by surface roughness. Although maintaining an optimum surface roughness is a major challenge in many manufacturing industries. Surface roughness during machining depends upon machining parameters such as cutting speed, feed rate and depth of cut. Also, tool vibrations during machining have significant influence in surface roughness. In this work an attempt is made to predict the surface roughness of machined components during the turning process by using machine learning techniques with vibration signals. By varying different machining parameters and keeping other tooling and material properties same, a range of surface roughness values can be obtained. For each condition, corresponding tool vibration signals were recorded. Our experimental setup involves

S S, Safeer, Sadique, Anwar, D, Navaneeth

Optimizing Cutting Parameters for Effective Turning of EN-31 Steel by Utilizing Vegetable-Based Cutting Fluids as a Coolant

05-18-01-0006

10/12/2024

The primary objective of this article is to study the improvement of machining efficiency of EN-31 steel by optimizing turning parameters using newly developed cutting fluids with different proportions of aloe vera gel and coconut oil, utilizing the Taguchi technique. Furthermore, performance metrics including material removal rate (MRR), surface roughness, and tool wear rate (TWR) were assessed. Analysis of variance (ANOVA) suggested that as cutting speed and feed increase, the MRR is positively influenced, but likewise tool wear is intensified. The surface roughness exhibited a positive correlation with cutting speed, and a negative correlation with increasing both cutting speed and feed. It was found that the maximum MRR value was attained at a cutting speed of 275 m/min, a feed rate of 1.00 mm/rev, and a cutting fluid composition of 30% aloe vera and 70% coconut oil. For the best surface smoothness, it is advisable to adjust the cutting speed to 350 m/min and the feed rate to 0.075

Premkumar, R., Ramesh Babu, R., Saiyathibrahim, A., Murali Krishnan, R., Vivek, R., Jatti, Vijaykumar S., Rane, Vivek S., Balaji, K.

Multi Response Optimization of Machining Heat Treated Aluminium Alloy Using Desirability Approach

2023-01-5186

02/23/2024

Aluminium alloys enrolled their applications in automobile sectors, agricultural equipment, machine tools and aerospace because of their weight-to-strength ratio. Aluminium alloy 7075-T651 is an inevitable material used in engineering sectors. Turning is a metal removal process, to obtain net geometrical aspects and better surface finish of the products. The machinability of the turning operation is based on different factors; however, turning factors and material of tool plays a significant position in the turning process. To identify the truthful cutting parameters to achieve multi-responses in turning operation, the experiment was designed via Response Surface Methodology (RSM) Central Composite Design (CCD) and the experimental results are analyzed under the desirability approach. By trialing 26 interpretations in the desirability approach; the optimal cutting parameter settings of speed 800 rpm, feed rate 0.140315 mm/rev and depth of cut 0.3501 mm have been revealed to enhance

Sundarrajan, D., Senthil Kumaar, J. S., Muthiah, A., Manikandan, A., Sivakumar, N. S.

Analysis of Influence on Machining Characteristics of Nimonic 80

2023-01-5173

02/23/2024

The quality of the finished product depends on the contribution of many factors along with the complex process involved to move forward towards the new product development. Many operations like turning, drilling, milling in metal machining deserves the quality as a predominant measurement. The tool and work piece plays a vital role in machining process which depends on machining parameters such as spindle speed, feed rate, depth of cut, approach angle. In the present work the turning operation was carried out on Nickel alloy (Nimonic 80) as a work piece and the carbide insert was used as a tool for performing the machining operations. The cutting parameters were optimized using Taguchi based grey relational analysis. Provided that, the ANOVA analysis to find the predominant factors that affects the quality were also determined. The experimental results were compared with the predicted results and found to be a promising agreement between the factors and responses.

Jashwanth, S., Rajaparthiban, J., Ganesamoorthy, R., Balaji, N., Padmavathi, K.R.

Characterization of Enhanced Magnetorheological Fluid Damper and Its Influence on Sustainable Hard Turning of SS410

2023-01-5133

02/23/2024

Sustainable manufacturing, a term that has been used in the recent past on numerous occasions. A primary reason for it being in limelight, is that it does not cause any damage to the environment and also to the personal involved. Additionally, another important parameter of concern is the energy consumed during the machining process. One major reason for higher energy consumption is because of the presence of tool vibration. There have been several attempts made to reduce vibration and though they have been proved to be effective, they could be not classified under sustainable manufacturing. When used as a semi-active damper in metal cutting, magnetorheological fluid (MRF) has proven to be successful in vibration suppression. MRF is an intelligent non-Newtonian fluid that can change its viscosity instantly when a magnetic field is applied to it. They've utilised it as a damper in a number of areas because of this quality and its toughness. One significant drawback is the settling of

Ajay Vasanth, X., Sam Paul, P., Lawrance, G., Rajkumar, V., Senthilkumar, K.

Application of Desirability Approach to Determine Optimal Turning Parameters

2024-01-5022

02/20/2024

Aluminum alloys are employed in agricultural equipment, aerospace sectors, medical instruments, machinery, automobiles, etc. due to their physical and mechanical characteristics. The geometrical shape and size of the parts are modified in turning operation by using a single-point cutting tool. A356 aluminum alloy is widely used in various engineering sectors, hence there is a necessity to produce A-356 components with quality. The inappropriate cutting parameters used in turning operation entail high production costs and reduce tool life. Box–Behnken design (BBD) based on response surface methodology (RSM) was used to design the experiments such that the experiment trials were conducted by varying cutting parameters like N-spindle speed (rpm), f-feed rate (mm/rev), and d-depth of cut (mm). The multi-objective responses, such as surface roughness (SR) and metal removal rate (MRR) were analyzed with the desirability method. The analysis of variance (ANOVA) represents the significant

Arunbharathi, R., Arish, R., Girith Chandru, S., Bhavandharshan, K., Gowthamprasath, A. D., Hari, K.

Optimization of Machining Parameters in Turning of Hastelloy C-276 by Considering Machinability and Chip Morphology Characteristics

2022-28-0526

12/23/2022

The present paper mainly focuses on the analysis and multi-factor optimization of cutting process parameters in turning Hastelloy C-276 using an integrated approach of Weighted Aggregated Sum Product Assessment (WASPAS) and criteria importance through inter-criteria correlation (CRITIC). To achieve this objective, a design of experiment (DoE) is employed for the three control parameters: cutting speed, feed rate, and cutting depth. The insert used for turning is a coated carbide insert (PVD: Ti-Al-N). Different responses are recorded: force, tool wear, and surface roughness in machining attributes, chip structure, chip thickness, chip thickness ration, shear angle, and friction coefficient in chip-tool interface indices. Uncertainty probabilistic study depends on Monte Carlo (MC) method applied. From the experimental results, the most impactful processing variable for force is cutting depth, surface roughness, and chip-tool interface indices are feed rate while cutting velocity for

Kannan, Venkatesan, Sundararajan, Devendiran

Influence of Various Parameters of Turning Low Carbon Steel with M2 HSS Tool Using Minimum Quantity Lubrication

2022-28-0533

12/23/2022

Turning is a widely used manufacturing process in mechanical machining industries, while the cost associated with this process is high due to the cost involved in changing tools or tool regrinding. All the parameters of turning, like feed rate, cutting speed, and depth of cut, substantially impact the tool wear, which subsequently reduces tool life. Cooling methods like flooding, Minimum Quantity Lubrication (MQL), etc., are incorporated to minimise these effects on the tool and workpiece interface. When using these cooling techniques, the process parameters involved play vital roles in increasing the effectiveness. This paper focuses on the effects of machining parameters on the tool and the workpiece quality. Experiments were conducted to study the impact of various input parameters of the turning process on the tool tip temperature, cutting forces, and tool wear, ultimately affecting the tool's life. The average cutting forces are reduced by 60 N, a 30 % reduction in the forces is

Sundaram Sundararajan, Anuj Srivathsa, B, Muralidharan

Cross-Training Made Possible by Common Control Platform

TBMG-3457906/01/2019

EMAG L.L.C. is the U.S. subsidiary of a major German machine tool builder that specializes in machine tools for the production of automotive, off-highway, agricultural, and oil field components. The company’s equipment ranges from basic round part turning centers to large-workpiece, five-axis machining centers; gear hobbing machines; and alternative equipment such as laser welding and electrochemical machining centers. This wide variety of machine tools requires an assortment of control technologies to power and manage the motion. For one customer requirement where a major agricultural equipment builder needed grinding, turning, and turn-grind machines, EMAG looked to Siemens for a standardized CNC solution.

Parametric Study, the Process Benefits, Optimization and Chip Morphology Study of Machining Parameter on Turning of Inconel 718 Using CVD Coated Tool and Nd: YAG Laser

2018-28-0029

07/09/2018

This paper presents the parametric study, process benefits, optimization and chip appearance of machining parameters on turning of the Inconel 718 using Nd: YAG laser source. To analyze the mentioned above effect on alloy 718, the cutting inserts of chemical vapor disposition coated (CVD) TiN/TICN/Al2O3 are used to turn at the time of machining. To evaluate the linear (mean effect plots) and interaction effect (3D surface plots) of laser parameters on the force, roughness and tool wear to keep the minimal, experiments of the L27 orthogonal array are done by selecting the controllable parameters viz speed, the rate of feed along with laser power. From the parametric study, increase in speed and laser power along with decrement in the rate of feed resulted in lower cutting force. But surface finish and tool wear reduced with a decline in speed and scale of feed and increased with increment in laser power. The investigations result in shows that with the application of moderate laser

Kannan, Venkatesan, Kannan, Vetri Velmurugan

‘Super-precision’ cylindrical roller bearings launched by SKF

16OFHP02_0802/01/2016

SKF recently launched two new “super-precision” cylindrical roller bearings series, targeted at the machine tool industry. The company says both of the new series deliver much improved bearing performance compared with existing SKF offerings. “The new cylindrical roller bearings are optimized solutions for OEMs that require greater load carrying capacity and higher speeds. While the SKF super-precision single row cylindrical roller bearings have a higher speed capability, the SKF super-precision double row cylindrical bearing are more suitable for heavier loads,” said Mauro Merlo, Super Precision Bearings Product Manager, SKF.

Broge, Jean L.

Very-High-Load-Capacity Air Bearing Spindle for Large Diamond Turning Machines

TBMG-19900

06/01/2014

Large-load-capacity oil hydrostatic bearings generate prohibitive amounts of heat in large sizes when run at speeds useful for diamond turning of optical components. The viscosity of air is more than three orders of magnitude less than the thinnest oil; therefore, the frictional heating of large-diameter air bearings is very small and very manageable. A formidable manufacturing problem with large air bearings is that the extremely low viscosity of air requires that the thickness of the bearing film is also very small. This very small bearing clearance of 5–8 micrometers means that the required accuracy of geometry and dimensions of air bearing components is extremely difficult to achieve.

Optimization of Cutting Parameters in Turning Process

2014-01-9097

01/15/2014

Predicting the main cutting force during turning is of great importance as it helps in setting the appropriate cutting parameters before machining starts. Again, optimization of cutting parameters is one of the most important elements in any process planning of metal parts as economy of machining operation plays a key role in gaining competitive advantage. This paper presents an experimental study of main cutting force in turning of AISI 1040 steel and developing a model of the main cutting force during turning using Response surface Methodology (RSM) as well as optimization of machining parameters using Genetic Algorithm (GA). The second order empirical model of the main cutting force in terms of machining parameters have been developed based on experimental results. The experimentation has been carried out considering three machining parameters: cutting speed, feed rate and depth of cut as independent variables and the main cutting force as the response variable. The formulated model

Bhuiyan, Tanveer Hossain, Ahmed, Imtiaz

Effect of Inoculation on Turning Machinability of Gray Cast Iron

2012-01-1823

09/17/2012

Turning is the widely machining process used for brake rotor manufacturing while turning cost is a one factors that many has a huge impact on manufacturing cost for second tier manufacturer so increase tool life is always needed developed in second tier manufacturer. This paper would like to investigate effect of microstructure and graphite morphology of gray cast iron which is the most widely materials use in brake rotor on machinability. The tested material was class FC250. The raw test was made of steel scrap, returned material at the ratio of 60 : 40. Controlled inoculation technique was inoculated in ladle compare with inoculated both in ladle and were in melting stream while pouring in horizontal greensand mould. The microstructure measured by optical microscopy and cutting force investigated by dynamometer. The experimental were observed to achieve the result of minimize cost among raw material, turning process cost, insert cost, and meet the product criteria of friction brake

Tongtae, Chanin, Dawan, Pimporn, Kumvong, Sukum

Pre-Finishing of SiC for Optical Applications

TBMG-987905/01/2011

A method is based on two unique processing steps that are both based on deterministic machining processes using a single-point diamond turning (SPDT) machine. In the first step, a high-MRR (material removal rate) process is used to machine the part within several microns of the final geometry. In the second step, a low-MRR process is used to machine the part to near optical quality using a novel ductile regime machining (DRM) process.

Aerospace Engineering 2011-02-09

11AERD020902/09/2011

Composite simulation helps fill gaps There is no turning back from using carbon-fiber reinforced plastics and other composite materials for aerospace parts. Simulation providers are finding new opportunities to help reduce cost and improve efficiencies in designing and making aerospace parts made of composites. Shifting gears smoothly Ric Kleine, a 30-year veteran of Cummins Inc. and former SAE Commercial Vehicle VP, seeks continuity over change as he moves into SAE's driver's seat.

Original Equipment

10OFHD0114_0301/14/2010

Case CE says new crawler dozer offers big performance, not weight Case Construction Equipment says its new 650L crawler dozer for residential job sites and confined commercial work areas retains the features of the Case crawler dozer line, such as hydrostatic drive, the operator compartment, and two undercarriage options. The 650L delivers 74 net hp (55 kW) through a four-cylinder, 4.5-L turbocharged Case Family IV engine with electronic fuel injection for maximum fuel efficiency and easier starts in cold weather. The Tier 3-certified engine is equipped with a high-pressure common-rail injection system and a charge air cooler that Case says reduces emissions and provides a cleaner, more efficient fuel burn.

Broge, Jean L.

Fanuc Painting Robot Boosts Production for Metal Finisher

TBMG-9576

10/01/2009

Classic Metal Finishing, based in Jackson, Mich., supplies components for the aerospace, motorcycle, racing, and medical industries. The plant was purchased in February, 2008 by Classic Metal Finishing and Classic Turning. Classic Turning performs high-end CNC machining of components and Classic Metal Finishing performs anodizing and dry film lubricant applications. Classic Metal Finishing’s anodizing line can anodize with two different types for corrosion inhibitor resistance, and can die aluminum in eight different colors. Dry film lubricant is applied to parts to help with high friction tolerance fits and moving assemblies.

Single-Mode WGM Resonators Fabricated by Diamond Turning

TBMG-279905/01/2008

A diamond turning process has made possible a significant advance in the art of whispering-gallery- mode (WGM) optical resonators. By use of this process, it is possible to fashion crystalline materials into WGM resonators that have ultrahigh resonance quality factors (high Q values), are compact (ranging in size from millimeters down to tens of microns), and support single electromagnetic modes.

Machining and turning centers take center stage

AEROMAR08_0303/01/2008

Makers of CNC machining equipment are incorporating more and better functionality into their products so users cope better with processing challenges such as those posed by tough new grades of aerospace materials. The name of the game in manufacturing is new product-be it a car, a computer, or a can opener-and making it available to the customer as quickly as possible. The new-product imperative applies no less to companies that make manufacturing equipment than it does to companies that make products with trendy mass-market appeal. The average consumer would not know it, but the makers of machining centers-Mazak, Haas, MAG, Mitsui Seiki, Stama, and others-pay close attention to trends, albeit not-mass market types, in cultivating new ideas for growth, all the while improving their own internal manufacturing processes to quickly translate their new ideas into finished goods.

Ponticel, Patrick

Aerospace Engineering & Manufacturing 2008-03-01

AEROMAR0803/01/2008

Making an impact in fastening Engineers at Electroimpact help the company get a leg up on the competition in automated fastening. Narrowing in on military requirements UAVs/UCAVs are increasingly important, with the accent on integration- and wider engine choice. Machining and turning centers take center stage Makers of CNC machining equipment are incorporating more and better functionality into their products so users cope better with processing challenges such as those posed by tough new grades of aerospace materials. Open (and often) communication As aircraft companies battle for market share, uniting design and manufacturing teams remains a key challenge.

Fabrication of Submillimeter Axisymmetric Optical Components

TBMG-191705/01/2007

It is now possible to fashion transparent crystalline materials into axisymmetric optical components having diameters ranging from hundreds down to tens of micrometers, whereas previously, the smallest attainable diameter was 500 m. A major step in the fabrication process that makes this possible can be characterized as diamond turning or computer numerically controlled machining on an ultrahigh-precision lathe. This process affords the flexibility to make arbitrary axisymmetric shapes that have various degrees of complexity: examples include a flat disk or a torus supported by a cylinder (see figure), or multiple closely axially spaced disks or tori supported by a cylinder. Such optical components are intended mainly for use as whispering-gallery- mode optical resonators in diverse actual and potential applications, including wavelength filtering, modulation, photonic generation and detection of microwaves, and research in quantum electrodynamics and quantum optics.

Fabrication of Submillimeter Axisymmetric Optical Components

TBMG-11620

05/01/2007

It is now possible to fashion transparent crystalline materials into axisymmetric optical components having diameters ranging from hundreds down to tens of micrometers, whereas previously, the smallest attainable diameter was 500 μm. A major step in the fabrication process that makes this possible can be characterized as diamond turning or computer numerically controlled machining on an ultrahigh-precision lathe. This process affords the flexibility to make arbitrary axisymmetric shapes that have various degrees of complexity: examples include a flat disk or a torus supported by a cylinder (see figure), or multiple closely axially spaced disks or tori supported by a cylinder. Such optical components are intended mainly for use as whispering-gallery-mode optical resonators in diverse actual and potential applications, including wavelength filtering, modulation, photonic generation and detection of microwaves, and research in quantum electrodynamics and quantum optics.