Optimisation of grinding parameters for wheel loading and dressing
Grinding is a finishing process often used to produce desired surface roughness with required precision and quality. The performance of grinding wheel significantly depends on the nature of the wheel, morphology of the abrasive grits and the grinding parameters namely speed, feed and depth of cut. As the wheel is performing its grinding operation, its cutting surface is being loaded with metal particles of the workpiece. This wheel loading also affects the surface finish of the workpiece. Hence monitoring the grinding wheel loading and dressing at proper time intervals becomes mandatory to get the desired surface finish. In the quest of developing a low cost monitoring system, it is good enough to analyse the wheel loading on widely used metal specimens such as mild steel, HCHCr steel and aluminium under optimised cutting conditions using the conventional silicon carbide and aluminium oxide wheels for better evaluation of the results. In this work the grinding parameters are optimised by using ANOVA technique. A full factorial experiment was carried out at 5% level of significance, i.e. at 95% confidence level.
The Influence of High-Speed Milling Strategies on 3D Surface Roughness Parameters
Abstract Nowadays in die-cast manufacturing high speed milling are used to increase quality, accuracy and speed of material processing, also to reduce processing costs and save machining time. This paper is devoted for research of high-speed processing regimes impacts and their effect on the surface roughness quality of the machined material and 3D surface parameter values. This paper contains recommendations for die-cast manufacturers, deploying HSM, to improve machining process and obtain required surface quality. Analysis of variance methodology is used in this research. Research identify the most appropriate HSM regimes, that most important is chosen material type or material mechanical properties, influencing kurtosis of the scale-limited surface (Sku) and height of the bearing area ratio curve (Stp). Feed rate is most significant for texture aspect ratio (Str) and strategy type – influencing parameter of arithmetic mean surface height (Sa) and valley fluid retention index (Svi).
Development and machinability assessment in turning Al/SiCp-metal matrix composite with multilayer coated carbide insert using Taguchi and statistical techniques
Abstract This paper presents the development of Al/SiCp (10% weight) metal matrix composite through a conventional casting process and studied its machinability characteristics in turning using multilayer TiN coated carbide insert under dry environment based on Taguchi's L 9 orthogonal array. Abrasion is found to be the dominant wear mechanism from the experimental study. Continuous fragmented saw tooth type of chip obtained during machining of Al/SiCp-MMC under dry environment. The colour of chip changes from metallic to partial blue and built-up-edge formation is noticed at extreme parametric conditions. Cutting speed is observed to be the most significant variable affecting the flank wear. Feed is found to be the most significant parameter for surface roughness. The regression models are highly significant because of higher R 2 value. The experimental and predicted values are very close to each other. Using grey relational analysis, the optimal parametric combination for multi-responses is found to be v3-f1-d3 and is greatly improved and noticed to be efficient while machining Al/SiCp-MMC.