Mohsen Marani Barzani

The Influence of Bismuth, Antimony, and Strontium on Microstructure, Thermal, and Machinability of Aluminum-Silicon Alloy

In this article, the influence of separate additions of bismuth, antimony, and strontium on microstructure, thermal, and machinability of Al-11%Si-2%Cu alloy (ADC12) has been reported. Additives depressed the aluminum-silicon eutectic growth temperature (TG) and altered the silicon morphology. Different silicon morphologies, namely flake, lamellar, and fibrous influenced the main cutting force, feed force, and surface roughness during turning. Workpieces with fibrous silicon morphology produced the highest cutting force, feed force, and surface roughness while that of bismuth-containing workpieces produced the lowest cutting force, feed force, and the best surface roughness due to the formation of bismuth compound which acts as lubricant during turning. The results showed that the highest TG is related to the best surface roughness and as such the best machinable alloy investigated.

Effect of machining parameters on cutting force when turning untreated and sb-treated al-11%si-1.8%Cu alloys using PVD coated tools

One of the important aspects of machining is the measurement of the cutting forces acting on the tool. The information of forces is required for evaluation of power requirements, designing tool holder, machine tool elements and fixture. In this research, the effect of cutting condition on cutting force when turning untreated Al-11%Si-1.8%Cu and Sb-treated alloys was investigated. PVD TiN coated insert as cutting tool under oblique dry cutting process utilized. Experiments were conducted at three different cutting speeds of 70, 130 and 250 m/min with feed rates of 0.05, 0.1 and 0.15 mm/rev, whereas depth of cut was kept constant at 0.05 mm. The results revealed that turning of Sb-treated alloys requires higher cutting force in comparison to untreated alloy. The cutting force values increased about four times with increasing feed rate from 0.05 mm/rev to 0.15 mm/rev. Furthermore, the cutting force decreased with increasing cutting speed from 70 m/min to 250 m/min.

Prediction, modeling and characterization of surface texturing by sulfuric etchant on non-toxic titanium bio-material using artificial neural networks and fuzzy logic systems

Abstract Multilayer feed forward network, radial biased function network, generalized regression neural network and adaptive network-based fuzzy inference system (ANFIS) were used to predict the surface roughness of Ti-13Zr-13Nb alloy in etching sulfuric acid. Subsequent processes – polishing, sandblasting and acid etching or SLA – were employed to modify the surface. Alumina particles for surface blasting and concentrated sulfuric acid for acid etching were utilized in this experiment. This was performed for three different periods of time (10, 20 and 30 s) and temperature (25, 45 and 60°C). Correspondingly, the Ti-13Zr-13Nb surfaces were evaluated using a field emission scanning electron microscope for roughening and a contact mode profilometer for the average surface roughness (Ra) (nm). Different configurations of neural networks and ANFIS approaches are examined in order to minimize the root mean square error. Consequently, the ANFIS model is selected by dividing the time and temperature into one and three spaces, respectively, using the Gaussian-shaped membership function. A mathematical model is attained from the best approach in terms of root mean square error to realize the relation of the surface roughness of Ti-13Zr-13Nb alloy in etching sulfuric acid and time and temperature as the effective parameters.

Effects of Cutting Condition on Surface Roughness when Turning Untreated and Sb-Treated Al-11%Si Alloys Using PVD Coated Tools

Surface roughness is an important output in different manufacturing processes. Its characteristic affects directly the performance of mechanical components and the fabrication cost. In this current work, an experimental investigation was conducted to determine the effects of various cutting speeds and feed rates on surface roughness in turning the untreated and Sb-treated Al-11%Si alloys. Experimental trials carried out using PVD TIN coated inserts. Experiments accomplished under oblique dry cutting when three different cutting speeds have been used at 70, 130 and 250 m/min with feed rates of 0.05, 0.1 and 0.15 mm/rev, whereas depth of cut kept constant at 0.05 mm. The results showed that Sb-treated Al-11%Si alloys have poor surface roughness in comparison to untreated Al-11%Si alloy. The surface roughness values reduce with cutting speed increment from 70 m/min to 250 m/min. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev.

Investigation into Effect of Tool Wear on Drilling Force and Surface Finish While Dry Drilling Aluminum 2024

Dry drilling of aluminum is environmentally friendly machining technique; in the meanwhile it is difficult to carry out due to aluminums gummy behavior and its tendency to adhere to cutting tools which diminishes hole quality. In spite of recent developments in cutting tool technology, HSS tools are still a cost effective choice due to relatively high toughness and feasibility to manufacture complex geometries of HSS drills besides its low price, make this tool a common choice for drilling soft materials such as aluminum. In this study effect of tool wear on thrust force and torque analyzed and hole quality assessed with respect to tool wear along tool life. Dry drilling on aluminum 2024, performed using HSS and HSCo drills at constant feed rate of 0.04 mm/rev and two cutting speeds of 28 and 94 m/min. Results revealed that the abrasive wear on flank face and BUE on chisel edge, margin and cutting lips were dominant mechanisms in all drills. It was found that with propagating the wear land on tool, thrust force and torque increased in both tools.

Investigation into Different Tool Coating performance While Turning Al6061

Cutting tool material technology in recent years has made great strides with substantial improvements in their strength, toughness, and wears resistance, which are designed to increase productivity, improve tool selection and aid to decrease costs and promote machining quality. This investigation presents the effect of various cutting speeds in turning of Al6061 with respect to different coatings. Experiments carried out under orthogonal dry cutting, and two different cutting speeds applied which were 250, 500 m/min. Feed rate and depth of cut kept constant respectively at 0.05 mm/rev and 0.5 mm in experiments. Three different carbide cutting tools have been used namely CVD tri-phase multilayer TiC/TiCN/TiN coated, PVD TiN coated and CVD TiC/Al2O3 coated. Tool performance was determined with respect to tool wear and surface finish in tests. Results obtained that tri-phase coated illustrated longest tool life, however best surface finish achieved by TiN coated tool. In addition adhered material which mainly formed in CVD tri-phase TiC/TiCN/TiN and TiC/Al2O3 coated tools, at higher cutting speed deteriorated surface finish in comparison to lower cutting speed.

White layer thickness prediction in wire-EDM using CuZn-coated wire electrode – ANFIS modelling

Wire cutting electrical discharge machining (WEDM) is a non-traditional technique by which the required profile is acquired using spark energy. Concerning wire cutting, precision machining is necessary to achieve high product quality. White layer thickness (WLT) is one of the most important factors for evaluating surface quality. Furthermore, WLT is among the most critical constraints in cutting parameters selection in WEDM. In this research, the adaptive neuro-fuzzy inference system (ANFIS) was used to predict the WLT in WEDM using a coated wire electrode. Experimental runs were conducted to validate the ANFIS model. The predicted data were compared with measured values, and the average prediction error for WLT was 2.61%. Based on the ANFIS model, minimum WLT is achieved at the lowest levels of peak current and pulse on-time with high level of pulse off-time.

Effect of Tool Wear on Tool Life and Surface Finish when Machining DF-3 Hardened Tool Steel

Hard turning is a dominant machining operation performed on hardened materials using single-point cutting tools. In recent years, hard turning operation has become more and more capable with respect to various machinability criteria. This work deals with machinability of hardened DF-3 tool steel with 55 ±1 HRC hardness at various cutting conditions in terms of tool life, tool wear mechanism and surface roughness. Continuous dry turning tests were carried out using coated, mixed ceramic insert with honed edge geometry. Two different cutting speeds, 100 and 210 m/min, and feed rate values of 0.05, 0.125 and 0.2 mm/rev were used with a 0.2 mm constant depth of cut for all tests. Additionally scanning electron microscope (SEM) was employed to clarify the different types of wear. As far as tool life was concerned, best result was achieved at lowest cutting condition whereas surface roughness values decreased when operating at higher cutting speed and lower feed rate. Additionally maximum volume of material removed is obtained at low cutting speed and high feed rate. Dominant wear mechanism observed during the experiments were flank and crater wear which is mainly caused by abrasive action of the hard workpiece material with the ceramic cutting tools.