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SEM722 Advanced Manufacturing Technology
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SEM722 Advanced Manufacturing Technology
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Course Code: SEM722
University: Deakin University
MyAssignmentHelp.com is not sponsored or endorsed by this college or university
Country: Australia
Question:
In Practical 1 you performed a set of experiments related to evaluating the machinability between two alloys under different machining operations, including an experiment to examine the surface roughness of the samples. Using the template provided, you will create a technical research paper based around these two experiments. Please read the carefully template in terms of how to write and structure your technical paper. Your paper will discuss the following elements.
Machinability ? the focus of your paper will be based on assessing the machinability of two different materials, stainless steel and aluminium. Using the experimental data collected from the practical by any means necessary, you will identify and report and discuss in your paper, which material has the better machinability and discuss why?
Limitations to machinability ? based on your observations from the practical and from the experimental data collected, you will discuss what is ‘machinability’ and why this so difficult to quantify?
Surface Roughness Analysis – based on the obtained surface profile results for each of the machined surfaces, you will draw inferences as the machinability of the respective material based on the surface roughness profile. You will discuss why this measurement is important and what insights it can provide with respect to the machine tooling tracks and overall finish of the material. You will also discuss the differences that result from changes in material and machining parameters on the surface roughness.
Answer:
Introduction
The term was originated around 1920 when life of tools is being considered as importance for economic viability, the engineers have found certain relation with these tools life with suitability of material and its ability to extended life. One of the procedure which is very common and readily adopted procedure is machining by chip removal, which holds the meaning of operation of metals with several lathe machine tools such as drilling, cutting and milling etc.
As discussed earlier, the potential advantage of cutting tools to perform different operation on metals with ability of metals to be machined is known as machinability. The decision making of machinability for material is not as simple as definition, it requires in depth study of material as well as theoretical part. There are several methods applied for deciding the parameters of machinability for certain material, some of these includes geometry of instrument, properties of apparatus, type of coolant during machining, the condition given for metals to be machined, and several others parameter. Most of the common operation done for the machining is drilling and milling, and especially this report we will include these two operations, so that we can decide the machinability of 316 stainless steel and aluminium. The speed of cutting and material of the device are the two imperious constraints while evaluating the machinability of a material. Materials having great machinability can be cut with less power and speed and surface finish will also good, makes less wear the instrument called as free machining (Eugene Thiele 2014).
The important reasons to study the 316 stainless steel and aluminium is it’s a very common form of metals which is being used for variety of application. By changing certain amount of composition in these two metals change the properties according to application and need of the Job. There are several techniques to analyse machinability. Some of these are by chip removal, quick stop technique, CDA’s Universal machinability index, classical standard technique etc. we are going through the procedure Quicks top techniques. The reason to choose these techniques is because of its simplicity, we can see the wear happened to material and tools with the help of magnifying glasses, and despite we have multipurpose CNC machine, which can perform different operation and provide accurate data with the help of dynamometer which is attached with it. The data obtained from these dynamometers will help in deciding the machinability of given metals easily.
As discussed earlier universal machinability test is more prominent in analysing machinability of steel and aluminium, but due to its requirement of enormous amount of resources it is limited scientific level. This is calculated from maximum production rate with giving constant time for tools and it is around 8 hours, this includes several workpiece materials this technique is out of scope at present (S. Yua 2016).
Another thing we would like to discuss about the machinability itself is complex process, it is difficult to clearly define the machinability and quantify it. The complexity and dependability of machining are based upon number of factors, most similar behaviour in material is being changed if its consideration is changed from tool life to cutting power or the quality of surface is good or bad.
For instance, the material for cutting tool is more important than material to be machined, both physical and geometry, that often machinability is expressed as “effective features of the work-tool amalgamation”. In this condition where number of parts being produced is large and not costly then protecting cutting tools is become important aspect of machinability, which significantly influences productivity and economy in machining, the extent of cutting forces which affects power feeding and dimensional accuracy surface finish the life of cutting tools also take part in performance of the industries, if appropriate material is given for cutting. For cutting tools point of view, the temperature arises due to cutting and formation of chip is important aspect of machinability.
For practical point of view all those aspects are not considered at a time, we are selecting some important aspect and categorise the material with few important aspects of machinability. For example, aluminium is soft, can be used where tough work in not required, whereas stainless steel is tough and can be used for longevity of life at rough places. Most of the time the machinability criteria are selected according to material to be used for milling drilling purposes. The response given by the material is also important for material section, some of the material behave unacceptable after getting heated during process, therefore coolant is used very carefully for that material,
Experimental details
The computer numerical control most widely used machine for cutting operation has acronym (CNC). In this machine material removed from workpiece with the help of different cutting tools which can be fixed on CNC machine, almost all kind of material cutting is possible through CNC machine. All the data for cutting and feeding is numerically controlled through amplifying signal of the dynamometer which is attached to it. That is it is largely used for analysing the machinability of material, because we can record all the data from the dynamometer. The figure of CNC machine with different part is given below.
There are commonly two type of CNC machine is available one is for drilling and another one is for milling. The determination of machining parameter by the operator of the machine is doing through G-Code, due to high level of tolerance and accuracy it is regarded as one of most manufacturing equipment in industries. Most of the cutting tools available for use in CNC machine includes Mill tolls, drill, tap face milling cutters etc. we can produce high level of geometry through this CNC machine.
Parameter for machine
For machinability test we must use two kind of machining operation, the first one is drilling and second one is milling. These operations will be conducted with the help of suitable carbide material cutting tools. The water tap is regularly flown to use is as coolant for the operation. This coolant helps to prevent the distortion in the tools, and prevent the property change in operating material, in case of out it is aluminium and steel. The ration of coolant in the water is about 20:1 or around 10 litre /min. The parameter for machine trial is described below.
The dimeter used for tools for milling operation is 12 mm, we have decided to keep the mill speed at 120 /min with the feed rate of 0.1 mm /tooth. The depth of cut given will be 1 mm to the workpiece and length of the cut will be 100 mm.
Diameter of tools is around 8 mm, with a feed rate of 0.1 mm/revolution, the depth of the cut given will be 10 mm and drilling speed will be 50 mm / min. As with the above given parameter we can perform the operation in controlled environment. All the operation is similar for both pieces.
Setting direction is one of the important things in CNC machine. For milling purposes, the axis of considered along horizonal direction i.e. in X and Y direction, but in case of drilling operation the direction will be downward i.e. Z direction. The movement of tools in drilling operation is unidirectional and it is upward or downward. The dynamometer of is of Kistler made amplifies the frequency generated during the operation and sent to record in the computer.
Quick Stop Test Method
During operation we must keep an eye on chip generation on the workpiece. The shapes of pieces generated is continuous chips, lamellar chips, segmented chips and discontinuous chip. The method especially adopted as quick stop method, consists of increasing the speed of cutting tool operation suddenly with the help of captive bolt gun. When contact between tools and workpiece happen, the shear pin gets tipped off and frozen chip is being collected from the workpiece. The frozen chip is analysed, and tool wear has been decided.
Tools wear and tear analysis
The analysis of tools with respect to wear and tear is one of the important primary analysis for machinability. This helps to determine toughness of material which is being passed recently. The observed tools in this regard is having flank wear and crater wear. This signifies that the tools contact was happened is with finished parts and crater wear is due to cutting failure of tools during the operation. This means that the second material is tougher that first one.
Optical surface profile is nothing but a kind of microscope which is used to measure the crest and trough on the surface of material which is to be tested. The basic principle of this microscope is that it is uses wavelength of light to look for the contrast of the wave and in comparison, with test surface and reference surface. The major parts of this profile consist of a shaft which is known as light shaft, a reflector which is used for reflecting the pillar like shape of from the test material which is passed through the objecting lens which magnifies before sending to the eyepiece. The other portion of the split bar is reflected from the surface which is known as reflector.
As per the analytical result obtained from frozen chip in quick stop method, we can say that the surface roughness value of steel and aluminium is as given below
Frictional force calculation
Table 1 – Surface roughness as per chip
Aluminium (Rc)
Steel (Rc)
Test 1
0.547722
0.502152
Test 2
0.557326
0.443058
Test 3
0.537334
0.524888
As per given data in the table the average Rc for aluminium (Al) = 0.5474
And for the average for steel = 0.49003
Rake angle for cutting tool = 12o
The average cutting force for Al = 45 N
The average cutting force for steel = 155 N
Shear angle Putting the all the relevant value in this equation.
Similarly, for Shear angle for Steel =
We know that,
Shear angle is given as (where = frictional angle)
The calculating for aluminium = 16o
And for steel = 22o
From Merchant’s circle solution we know that,
tan = (Coefficient of friction), then for aluminium tan16o = 0.2876
Similarly, for steel tan22 = 0.404
Now we have Fc, , α
From Marchant’s circle solution we know that
Again, arranging the above equation, we get
(Putting the respective value in this equation
= 3.18 N N
Similarly,
Further, from the equation,
Frictional force F = Fc*Sinα+Ft*Cosα (Putting the value for aluminium)
F(al) = 45*Sin12o + 3.18*Cos12o = 45*0.208+3.18*0.98 = 12.48 N
Similarly, F(SS) = 155*Sin12o + 27.3204*Cos12o = 35.36 N
From above calculation the frictional force for aluminium is 12.48 N and for steel is 35.36 N
Aluminium is providing less resistance ass compared to stainless steel
Results
The data obtained from dynamometer is being graphed for aluminium and stainless steel, for each of the operation like Drilling and milling. During milling process the force applied along x axis which is pivot and Y axis which is Hub with respect to time is noted, similarly for drilling operation, the force applied along Z axis, and torques applied to rotate the spindle is noted with respect to time. Each operation was conducted for the time of 20 seconds, the results are as follows.
The operation parameter is given as follows for aluminium
Table 2 – Parameter for aluminum
DynoWare
Version 2.5.3.8
Path:
C:UsersjuniorDesktopIQYT2 SEM722 – retest
Filename:
Test 2 – Aluminium run 02 – roughing cut.dwd
Config ID:
Test 2 – Aluminium run 02 – roughing cut.cfg
Setup ID:
0
Manipulated:
0
Filename 1:
Filename 2:
Date:
Thursday, 12 July 2018
Time:
3:08:05 PM
Sampling rate [Hz]:
5000
Measuring time [s]:
20
Delay time [s]:
0
Cycle time [s]:
0
Cycles:
1
Samples per channel:
100001
Cycle interval:
0
Cycle No:
1
Table 3 – Parameter for steel
DynoWare
Version 2.5.3.8
Path:
C:UsersjuniorDesktopIQYT2 SEM722 – retest
Filename:
Test 3 – 316 Stainless Steel – roughing cut.dwd
Config ID:
Test 3 – 316 Stainless Steel – roughing cut.cfg
Setup ID:
0
Manipulated:
0
Filename 1:
Filename 2:
Date:
Thursday, 12 July 2018
Time:
3:12:37 PM
Sampling rate [Hz]:
5000
Measuring time [s]:
20
Delay time [s]:
0
Cycle time [s]:
0
Cycles:
1
Samples per channel:
100001
Cycle interval:
0
Cycle No:
1
The graph for drilling operation for aluminium is given below
As in the figure given above, the force required to drill the aluminium is quite less than that of steel, second thing we can see that the drilling force for steel is equally distributed whereas force exerted on aluminium is most of the time negatively distributed, this is due to the elastic behaviour of steel, which cannot be seen in aluminium because of plastic behaviour.
The torque required for drilling is also is almost five time that of aluminium, first shows the negative side force due to compression and after middle portion penetration it goes to positive side, it is due to elongation. We can the graph for steel is denser, because there is always resisting force given by the material to the drill due to elastic behaviour of steel.
The force required for milling operation in steel is almost 2.5 time greater than the aluminium the force required for aluminium is in the range of (-180N
My Assignment Help. Advanced Manufacturing Technology [Internet]. My Assignment Help. 2021 [cited 18 December 2021]. Available from: https://myassignmenthelp.com/free-samples/sem722-advanced-manufacturing-technology/assessment-of-machinability-of-aluminum-and-steel.html.
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