Predicting the surface roughness in the dry machining of duplex stainless steel (DSS)

This paper examines the influence of cutting parameters, namely cutting speed, feed and depth of cut onto surface roughness after DSS turning process. The study included developing a mathematical model to determine the surface roughness. Verification research has been carried out on CNC lathe; hence the test plan has been adjusted to the possibility of programmable machines controlling GE Fanuc Series 0-T. The comparison of results obtained by given experimental plan was performed in industrial company

Microhardness changes gradient of the duplex stainless steel (DSS) surface layer after dry turning

The article presents the gradient of microhardness changes as a function of the distance from the material surface after turning with a wedge provided with a coating with a ceramic intermediate layer. The investigation comprised the influence of cutting speed on surface integrity microhardness in dry machining. The tested material was duplex stainless steel (DSS) with two-phase, ferritic-austenitic structure. The tests have been performed under production conditions during machining of parts for electric motors and deep-well pumps

Investigation of the physical parameters of duplex stainless steel (DSS) surface integrity after turning

The article presents the influence of machining parameters on the microhardness of surface integrity (SI) after turning by means of a coated sintered carbide wedge with a coating with ceramic intermediate layer. The investigation comprised the influence of cutting speed on the SI microhardness in dry machining. The material under investigation was duplex stainless steel with two-phase ferritic-austenitic structure. The results obtained allow for conclusions concerning the exploitation features of processed machine parts

Evaluating hole quality in drilling of Al 6061 alloys

Hole quality in drilling is considered a precursor for reliable and secure component assembly, ensuring product integrity and functioning service life. This paper aims to evaluate the influence of the key process parameters on drilling performance. A series of drilling tests with new TiN-coated high speed steel (HSS) bits are performed, while thrust force and torque are measured with the aid of an in-house built force dynamometer. The effect of process mechanics on hole quality, e.g., dimensional accuracy, burr formation, surface finish, is evaluated in relation to drill-bit wear and chip formation mechanism. Experimental results indicate that the feedrate which dictates the uncut chip thickness and material removal rate is the most dominant factor, significantly impacting force and hole quality. For a given spindle speed range, maximum increase of axial force and torque is 44.94% and 47.65%, respectively, when feedrate increases from 0.04 mm/rev to 0.08 mm/rev. Stable, jerk-free cutting at feedrate of as low as 0.04 mm/rev is shown to result in hole dimensional error of less than 2%. A low feedrate along with high spindle speed may be preferred. The underlying tool wear mechanism and progression needs to be taken into account when drilling a large number of holes. The findings of the paper clearly signify the importance and choice of drilling parameters and provide guidelines for manufacturing industries to enhance a part's dimensional integrity and productivity

Predicting the surface roughness in the dry machining of duplex stainless steel (DSS)

This paper examines the influence of cutting parameters, namely cutting speed, feed and depth of cut onto surface roughness after DSS turning process. The study included developing a mathematical model to determine the surface roughness. Verification research has been carried out on CNC lathe; hence the test plan has been adjusted to the possibility of programmable machines controlling GE Fanuc Series 0-T. The comparison of results obtained by given experimental plan was performed in industrial company

Investigation of selected surface integrity features of duplex stainless steel (DSS) after turning

The article presents surface roughness profiles and Abbott - Firestone curves with vertical and amplitude parameters of surface roughness after turning by means of a coated sintered carbide wedge with a coating with ceramic intermediate layer. The investigation comprised the influence of cutting speed on the selected features of surface integrity in dry machining. The material under investigation was duplex stainless steel with two-phase ferritic-austenitic structure. The tests have been performed under production conditions during machining of parts for electric motors and deep-well pumps. The obtained results allow to draw conclusions about the characteristics of surface properties of the machined parts

Monitoring of focusing tube wear during abrasive waterjet (AWJ) cutting of AISI 309

The paper deals with the investigating the possibility of using vibrations as a potential source of information for the detection of the malfunctions during the abrasive supplying and focusing tube wear in the process of AWJ. The tested material was the stainless steel AISI 309. Variable factors in the experiment were the abrasive mass flow ma and the focusing tube diameter df. The scanned vibration signal of the material was subjected to frequency analysis. With the increase of the abrasive mass flow, the shift of the amplitudes will follow the opposite direction and decrease. Frequency spectra of all assessed signals are similar by shape in the high-frequency area

Sustainable cooling strategies to reduce tool wear, power consumption and surface roughness during ultrasonic assisted turning of Ti-6Al-4V

Issues related to the machinability of difficult-to-machine materials such as Titanium and Nickel base superalloys are well explicated in the literature. In this regard, a novel study, applying ultrasonic vibration along with MQL and LCO2, is proposed to enhance the machinability of Ti-6Al-4V. In this regard, this article attempts to analyze machinability of Ti-6Al-4V in conventional and Ultrasonic Assisted Turning (UAT) under dry, wet, MQL and LCO2. The experiments are performed on an in-house developed ultrasonic assisted turning setup, keeping all the machining parameters constant. The main tool wear mechanisms observed are diffusion, adhesion, abrasion, and built-up edge formation in both cutting strategies. Moreover, the LCO2 and ultrasonic vibration significantly reduce specific cutting energy without compromising the surface roughness and tool life. Ultimately, the LCO2, along with ultrasonic assisted turning, promotes sustainability in the machining of Ti-6Al-4V

Design of the model for the on-line control of the AWJ technology based on neural networks

279-287The paper focuses on the problem of prediction of surface roughness in AWJ process and contributes to the online monitoring of the hydro-abrasive material disintegration process and its possible control. The main scope of the paper is to contribute to the usage of an artificial neural network as a decisive part in the surface roughness prediction and to outline a suitable online control mechanism. In paper a series of experiments are conducted to predict surface roughness and to use phenomena like acoustic emission and vibrations that accompany the cutting process to use in a possible process control. The model of artificial neural network is created in the MATLAB environment. In total, 150 configurations of multilayer perceptron with different configurations of numbers of neurons in hidden layers are developed. Two training functions, the Bayesian regularization and the Levenberg–Marquardt algorithm, are used during the network training. The results of the realized experiment have shown that the network with feedforward topology is able to predict correct value of the profile roughness parameter