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The purpose of this paper is to investigate the influence of turning parameters such as cutting speed, feed rate and depth of cut on tool flank wear and machined surface…
The purpose of this paper is to investigate the influence of turning parameters such as cutting speed, feed rate and depth of cut on tool flank wear and machined surface quality of AISI 304 stainless steel during environment friendly turning under nanofluid minimum quantity lubrication (NMQL) conditions using PVD-coated carbide cutting inserts.
Turning experiments are conducted as per the central composite rotatable design under the response surface methodology. ANOVA and regression analysis are employed to examine significant cutting parameters and develop mathematical models for VB (tool flank wear) and Ra (surface roughness). Multi-response desirability optimization approach is used to investigate optimum turning parameters for simultaneously minimizing VB and Ra.
Optimal input turning parameters are observed as follows: cutting speed: 168.06 m/min., feed rate: 0.06 mm/rev. and depth of cut: 0.25 mm with predicted optimal output response factors: VB: 106.864 µm and Ra: 0.571 µm at the 0.753 desirability level. ANOVA test reveals depth of cut and cutting speed-feed rate interaction as statistically significant factors influencing tool flank wear, whereas cutting speed is a dominating factor affecting surface roughness. Confirmation tests show 5.70 and 3.71 percent error between predicted and experimental examined values of VB and Ra, respectively.
AISI 304 is a highly consumed grade of stainless steel in aerospace components, chemical equipment, nuclear industry, pressure vessels, food processing equipment, paper industry, etc. However, AISI 304 stainless steel is considered as a difficult-to-cut material because of its high strength, rapid work hardening and low heat conductivity. This leads to lesser tool life and poor surface finish. Consequently, the optimization of machining parameters is necessary to minimize tool wear and surface roughness. The results obtained in this research can be used as turning database for the above-mentioned industries for attaining a better machined surface quality and tool performance under environment friendly machining conditions.
Turning of AISI 304 stainless steel under NMQL conditions results in environment friendly machining process by maintaining a dry, healthy, clean and pollution free working area.
Machining of AISI 304 stainless steel under vegetable oil-based NMQL conditions has not been investigated previously.
Additive manufacturing (AM) offers potential solutions when conventional manufacturing reaches its technological limits. These include a high degree of design freedom…
Additive manufacturing (AM) offers potential solutions when conventional manufacturing reaches its technological limits. These include a high degree of design freedom, lightweight design, functional integration and rapid prototyping. In this paper, the authors show how AM can be implemented not only for prototyping but also production using different optimization approaches in design including topology optimization, support optimization and selection of part orientation and part consolidation. This paper aims to present how AM can reduce the production cost of complex components such as jet engine air manifold by optimizing the design. This case study also identifies a detailed feasibility analysis of the cost model for an air manifold of an Airbus jet engine using various strategies, such as computer numerical control machining, printing with standard support structures and support optimization.
Parameters that affect the production price of the air manifold such as machining, printing (process), feedstock, labor and post-processing costs were calculated and compared to find the best manufacturing strategy.
Results showed that AM can solve a range of problems and improve production by customization, rapid prototyping and geometrical freedom. This case study showed that 49%–58% of the cost is related to pre- and post-processing when using laser-based powder bed fusion to produce the air manifold. However, the cost of pre- and post-processing when using machining is 32%–35% of the total production costs. The results of this research can assist successful enterprises, such as aerospace, automotive and medical, in successfully turning toward AM technology.
Important factors such as validity, feasibility and limitations, pre-processing and monitoring, are discussed to show how a process chain can be controlled and run efficiently. Reproducibility of the process chain is debated to ensure the quality of mass production lines. Post-processing and qualification of the AM parts are also discussed to show how to satisfy the demands on standards (for surface quality and dimensional accuracy), safety, quality and certification. The original contribution of this paper is identifying the main production costs of complex components using both conventional and AM.
Briefly reviews previous literature by the author before presenting an original 12 step system integration protocol designed to ensure the success of companies or…
Briefly reviews previous literature by the author before presenting an original 12 step system integration protocol designed to ensure the success of companies or countries in their efforts to develop and market new products. Looks at the issues from different strategic levels such as corporate, international, military and economic. Presents 31 case studies, including the success of Japan in microchips to the failure of Xerox to sell its invention of the Alto personal computer 3 years before Apple: from the success in DNA and Superconductor research to the success of Sunbeam in inventing and marketing food processors: and from the daring invention and production of atomic energy for survival to the successes of sewing machine inventor Howe in co‐operating on patents to compete in markets. Includes 306 questions and answers in order to qualify concepts introduced.
AS a successful manufacturer of precision products for the booming aerospace industry, High Temperature Engineers is under continuous pressure to improve productivity…
AS a successful manufacturer of precision products for the booming aerospace industry, High Temperature Engineers is under continuous pressure to improve productivity. With a healthy order book, the company puts a major emphasis on optimising production and reducing lead times in component manufacture. Playing an important role in achieving these aims are ten Traub CNC turning machines.
THE inclined‐bed turning machine is almost universally adopted throughout industry, but the flat‐bed design still has its place in modern manufacturing. For example, Dowty…
THE inclined‐bed turning machine is almost universally adopted throughout industry, but the flat‐bed design still has its place in modern manufacturing. For example, Dowty Rotol in Gloucester has invested over £700,000 in eight flat‐bed, computer‐controlled turning machines from Glidemeister UK Ltd, Luton, to produce precision components for military and civilian aircraft, and defence equipment.
SURFACE treatment specialists Abrasive Developments reports that more and more companies in the aerospace industry are turning to its dry and wet blasting processes.
BRIDGEPORT has launched three large‐capacity, vertical machining centres (VMCs) and two Interact manual‐toolchange CNC milling machines in response to market demand from the UK and overseas.
Aluminium silicon carbide reinforced metal matrix composite (Al/SiC‐MMC) materials are rapidly replacing conventional materials in various automotive, aerospace and other…
Aluminium silicon carbide reinforced metal matrix composite (Al/SiC‐MMC) materials are rapidly replacing conventional materials in various automotive, aerospace and other industries. Accordingly, the need for accurate machining of composites has increased enormously. The present work analyzes the machining of Al/SiC composites for surface roughness. An empirical model has been developed to correlate the machining parameters and their interactions with surface roughness. Response surface regression and analysis of variance are used for making the model. The developed model can be effectively used to predict the surface roughness in machining Al/SiC‐MMC composites. The influences of different parameters in machining Al/SiC particulate composites have been analyzed through contour graphs and 3D plots.
Noble & Lund/FMT have acquired the Kearns Richards product range of horizontal boring machines and vertical turning centres. The range of machines is complementary to the FMT range of machining centres, aerospace profilers and gantry machines manufactured by Noble & Lund.