The Study Of Wear Process On Uncoated Carbide Cutting Tool In Machining Titanium Alloy

The uncoated carbide cutting tools were used in turning titanium alloy Ti6Al4V bar with hardness of 340HV. The main objective to find the wear behaviour of the cutting tool based on the flank wear data. The experiments were performed under dry cutting condition at various combinations of cutting speed and feed rate. The cutting speeds selected in the experiment were 15, 25, 35 and 45 m/min. Meanwhile the feed rates were used at 0.02 and 0.04 mm/rev. In this research depth of cut, doc was kept constant at 0.5 mm for all combinations of cutting parameters. Tool wear was measured under optical microscope and the data of flank wear which was gained through the experiment has been analysed. According to these graph shown that the affected of cutting parameters onto tool wear. The experiment’s result showed that the flank wear increased with the cutting speed and feed rate. The flank wear occurs gradually at beginning of machining and at the end of failure when Vbavg reached 0.3 mm where flank wear occurs

TOOL LIFE INVESTIGATION IN DRY TURNING OF INCONEL 718 WITH PVD TiAlN-COATED WC INSERT

Performance of tool life for coated carbide tool during turning Inconel 718 in dry condition was studied in order to increase the efficiency in turning process and reduce the machining cost. Coated carbide tool with thin layer of PVD TiAlN, CNMG 120408-QM 1105 was used to turn Inconel 718 with hardness 20.25 HRC. Taguchi method with the orthogonal array L9 was use in this experiment with the parameter v=60, 70, 80m/min, f=0.2,0.25,0.3mm/rev and d=0.3, 0.4, 0.5mm. Signal-to-noise ratio and analysis of variance (ANOVA) were employed to study the performance of tool life. According to results, cutting speed was significantly influence to the tool life, followed by feed rate and depth of cut. Increment in speed and feed rate will increase flank wear and shorten the tool life. v=60m/min, f=0.2mm/rev and d=0.3mm is the optimum parameter for tool life. It was discovered that flank wear rate gradually increase in the initial machining and accelerate significantly after flank wear width reach 0.1mm. Flank wear, crater wear, notch wear and nose wear are the wear occurs on the carbide tool during turning Inconel 718. Through the SEM, abrasion, attrition and adhesion are the wear mechanisms which can be seen on the cutting tool

PREDICTION SURFACE ROUGHNESS IN HIGH-SPEED MILLING OF INCONEL 718 UNDER MQL USING RSM METHOD

This paper investigates the effect of cutting speed, feed rate, and depth of cut on the surface roughness of Inconel 718 when milled under minimum quantity lubrication. The response surface methodology (RSM) was employed in the experiment, and a Box–Behnken design was used to determine the cause and effect of the relationship between the control variables and the response. The investigated milling parameters were cutting speed (100, 135, and 170 m/min), feed rate (0.15, 0.2, and 0.25 mm/rev), and depth of cut (0.6, 0.8, and 1.0 mm). The results showed that the interaction between the feed rate, fz, and the radial depth of cut, ae, was the primary factor controlling surface roughness. The responses of various factors were plotted using a three-dimensional surface graph. The quadratic empirical models were developed with a 95% confidence level. The optimum condition required for minimum surface roughness include cutting speed of 136 m/min, feed rate of 0.1 mm/rev, axial depth of cut of 0.5 mm, and radial depth of cut of 1.38 mm. With this optimum condition, a surface roughness of 0.117 µm was obtained

Landslide susceptibility mapping: effect of spatial resolution towards the prediction of landslide prone area in a tropical catchment.

Landslide has become a common problem especially in tropical countries such as in Malaysia. This study was carried out in Fraser Hill Catchment using a GIS based deterministic slope stability analysis model, that combine infinite slope stability and steady state hydrology assumptions to quantify the stability called SINMAP. The model requires some inputs. Historical landslide inventory for the catchment were obtained from interpretation of multispectral SPOT 5 image and Global Positioning Survey (GPS) survey. Topographic maps at scale of 1:50,000 were used to construct Digital Elevation Model (DEM). Soil strength parameters and hydrologic parameters were gathered from in situ test as well as previous records. The purposes of this study were to map the landslide susceptibility of Fraser Hill Catchment and to test the usage of different DEM spatial resolution towards the accuracy of the model. Landslide susceptibility map for the study area was produced as the output of this model. The result will be compared with the actual location of slope failure that occur within the catchment to assess the model performance. Results showed that, for this catchment, SINMAP gives good results in predicting the landslide with 68% of the current landslide inventory fall within unstable class as their calculation of Stability Index (SI) are less than 1. Results from the spatial resolution analysis showed that 20 and 30 meter resolution gave optimum result compared to others

Prediction of Cutting Force in End Milling of Inconel 718

Inconel is prominently known as a hard material to be machined. Due to stability during extreme temperature, it is widely used in aerospace components especially turbine blade (Kitagawa et al. , 1997, Ulutan and Ozel, 2011). Some processes require ball end type due to intricate and complex shape. This curve cutting tip tool reduces stress concentration. However, the complex shape of round nose geometry exhibit tool wear mode that different than flat end milling tool (Aspinwall et al. , 2007). Studies from previous researchers found that the interrupted cutting process causes flaking especially during machining high tensile strength (Figure 1) (Kasim et al. , 2013). This paper presents the effect of cutting speed, feed rate, and depth of cut on the cutting force when machining Inconel 718 under minimum quantity lubrication. The response surface methodology (RSM) was used in the experiment, and a Box–Behnken design was used to determine the cause and effect of the relationship between the four cutting parameters and cutting force. The investigation milling parameters were cutting speed (100, 120, and 140 m/min), feed rate (0.1, 0.15, and 0.2 mm/tooth), axial depth of cut (0.5, 0.75, and 1.0 mm) and radial depth of cut (0.2, 1, and 1.8 mm). The result shows that the radial depth of cut was the dominating factor controlling cutting force, it was followed by axial depth of cut and feed rate. The relationship between cutting force of various factors was expressed in a three-dimensional response graph (Figure 2). The second order prediction cutting force equation (1) was developed with a 95% confidence level. The optimum condition required for minimum cutting force include cutting speed of 110 m/min, feed rate of 0.1 mm/rev, axial depth of cut of 0.5 mm, and radial depth of cut of 0.25 mm. The error between the predictive model and the actual of cutting force was less than 3%. With this optimum condition, a cutting force of 144N was obtained

Tool Life Of TiAlN PVD Coated Carbide Tool In High-Speed End Milling Of Untreated Inconel 718 Under Minimum Quantity Lubrication Condition

This paper presents the tool life of the end milled Inconel 718, which is part of a material that is difficult to be machined. Previous researchers found that tool life in machining aged Inconel 718 is shorter compared with other materials. However, this observation required further investigation. Thus, a raw grade Inconel was proposed in this experiment. The experiments were performed using TiAlN-coated carbide. The studied milling parameters were the cutting speed, Vc, from 90 to 150 m/min; feed rate, fz, from 0.15 to 0.25 mm/rev; depth of cut, ap, from 0.3 to 0.5 mm; and radial depth of cut, ae=1 mm. The application of the cutting fluid used in this experiment was a minimum quantity lubricant, which had the advantage of cooling effectiveness and low consumption of cutting fluid. The results showed that the feed rate, fz, was the primary factor controlling the tool life. The combination of Vc=115 m/min, fz=0.15 mm/tooth, as well as ap=0.5 mm and ae=0.15 mm gave the longest tool life that served 95.38 min in operation

Design Consideration For Design A Flat And Ring Plastics Part Using Solidworks Software

Various considerations on design of plastic injection moulded parts were applied in initial stage to prevent any defects of end products. Therefore, the objective of this project is to design the plastic injection moulded part by taking consideration on several factors such as draft angle, corner radius and location of gate. In this project, flat plastic part, ring plastic part, core inserts for flat and ring plastic part were designed using SolidWorks software. The plastic part was drawn in sketching mode then the 3D modeling of solid part was generated using various commands. Considerations of plastic part such as draft angle and corner radius with location of gate was considered in the design stage. Finally, it was successfully designed the two plastic parts with their respectively insert by using SolidWorks software. The flat plastic part and ring plastic part were designed for the purpose for future researches for study the weld lines, meld lines, air trapped and geometrical size of the product. Thus, by designing the flat plastic part and ring plastic part having core insert on each part, the completed mould design of two plate mould can be considered. This is because, plastic injection parts are needed to be designed properly in order to neglect any defect when the mould was made

Generation Of A Decision Support System To Enhance The Efficiency Of Lean Manufacturing

Lean manufacturing (LM) is an established process that employs an array of instruments to eradicate waste. A variety of methods have been applied (some more successfully than others) to enhance the effectiveness of this process. This study delves into the introduction of the Intelligent Lean Tools Simulation (iLeTS) to overcome the deficiencies in the LM process and reduce the failure ratio. Fabricated with the use of modelling software, the performance of iLeTS was enhanced by way of an amalgamation involving the visual basic application (VBA) and the multi agent system (MAS). This merging served to enhance the user friendliness of iLeTS, which in turn reduced the required period of usage. Face validity and a usability study were harnessed to evaluate the performance of iLeTS. While face validity was used to authenticate the multi-agent system flow in iLeTS; the usability study was engaged to determine the proficiency of iLeTS when it comes to managing a number of arbitrarily occurring incidents. Subsequent to a thorough examination of a wide range of simulation results (deriving from authentic data), we arrived at the conclusion that (a) the iLeTS is suitable for the automation of the manufacturing process, and (b) the iLeTS can be relied upon for making prompt and appropriate choices

Landslide susceptibility mapping: effect of spatial resolution towards the prediction of landslide prone area in a tropical catchment

Landslide has become a common problem especially in tropical countries such as in Malaysia. This study was carried out in Fraser Hill Catchment using a GIS based deterministic slope stability analysis model, that combine infinite slope stability and steady state hydrology assumptions to quantify the stability called SINMAP. The model requires some inputs. Historical landslide inventory for the catchment were obtained from interpretation of multispectral SPOT 5 image and Global Positioning Survey (GPS) survey. Topographic maps at scale of 1:50,000 were used to construct Digital Elevation Model (DEM). Soil strength parameters and hydrologic parameters were gathered from in situ test as well as previous records. The purposes of this study were to map the landslide susceptibility of Fraser Hill Catchment and to test the usage of different DEM spatial resolution towards the accuracyof the model. Landslide susceptibility map for the study area was produced as the output of this model. The result will be compared with the actual location of slope failure that occur within the catchment to assess the model performance. Results showed that, for this catchment, SINMAP gives good results in predicting the landslide with 68% of the current landslide inventory fall within unstable class as their calculation of Stability Index (SI) are less than 1. Results from the spatial resolution analysis showed that 20 and 30 meter resolution gave optimum result compared to others

The Effect of Edm Die-sinking Parameters on Material Removal Rate of Beryllium Copper Using Full Factorial Method

The effect of electrical discharge machining (EDM) die-sinking parameters on material removal rate (MRR) of Beryllium Copper (BeCu) was studied. EDM die-sinking is one of the important non-traditional machining processes and it is widely accepted as a standard machining process in the manufacturing of forming tools to produce mould and die. The appropriate parameters were selected to study the influence of operating parameters of BeCu on MRR. Electrolytic copper was selected as electrode with positive polarity. The experiment was done using SODICK AQ35L EDM machine. Two level approach of full factorial design of experiment was applied to design the experimental and the data was analyzed by using analysis of variance (ANOVA) and the optimal combinations of the process parameters were predicted. It is found that peak current was the most significant factor affecting the MRR. Further, pulse on time and pulse off time must be combined with other factors in order to influence the machining characteristics. Finally, machine voltage shows less significant factor for the EDM die-sinking process on BeCu