Print ISSN: 1681-6900

Online ISSN: 2412-0758

Keywords : Surface roughness

Surface Roughness Evaluation in WEDM Using Taguchi Parameter Design Method

S.H. Aghdeab; V.N. Najm; A.M. Saleh

Engineering and Technology Journal, 2018, Volume 36, Issue 1, Pages 60-64

Machining of hard metal is difficult by conventional method to obtain high accuracy where the dimensional accuracy is the main factor. Wire electrical discharge machining (WEDM) extensively used, which is mostly used in machining of conductive materials by using precisely controlled sparks that occur between a very thin wire and a workpiece in the presence of a dielectric fluid. This study serves in studying surface roughness (SR) of high speed steel (HSS) using taguchi method to design the experiment, this was achieved with utilizing different wire cut machining parameters and study the behavior of these control parameters such as pulse duration (μs), pulse interval (μs), Servo feed and Servo voltage (V) on surface roughness. It can be noticed that when servo voltage and servo feed increase the surface roughness decreases and when pulse duration and pulse interval increase the surface roughness increases too, and It was found with using taguchi parameter design that the best machining variables of combination setting is Servo Voltage (22) volts, Pulse on time (110) μs, servo feed (450) mm/min and Pulse off time (30) μs to reach to the minimum value of surface roughness and hence better surface finish.

Modeling and Optimization of Machine Parameters Using Simulated Annealing Algorithm (SAA)

Aqeel Sabree Bedan; Alaa Hassan Shabeeb; Hassan Nemaha Al-Sobyhawe

Engineering and Technology Journal, 2016, Volume 34, Issue 7, Pages 1473-1482

The present work deals with the mathematical modeling and analysis of machining response such as the surface roughness in the milling of aluminum alloy (AA6061). There are several machiningvariableslikerotational speed, depth of cut and feed rate used to find the quality of surface quality.
Simulated Annealing Algorithm (SAA) is utilized to develop an effective mathematical model to predict optimum level. In simulated annealing algorithm (SAA), an exponential cooling program depending on Newtonian cooling is applied and experimentation is done on choosing the number of iterations for each step. The SAA is used to predict the cutting variables (rotational speed,feed rate and depth of cut) on productquality in dry millingof Al 6061 based on Taguchi‘s orthogonal array of L9 and analysis of variance (ANOVA) were apply to determination the important factors that effect on surface quality.
At last, tests were conducted to confirm by making a comparison between the experimental results and the model developed. The experimental results have shown the performance ofmachining in the milling can be improved effectively using this algorithm.

Surface Roughness Prediction Using Circular Interpolation Based on Artificial Neural Network in Milling Operation

Maan Aabid Tawfiq; Ahmed A.A. Duroobi; Safaa K. Ghazi

Engineering and Technology Journal, 2016, Volume 34, Issue 5, Pages 983-998

This paper presents a method togenerate tool path and get G-codes for complex shapes depending on mathematical equations without using the package programs that use linear interpolation. Circular interpolation (G02, and G03) were used to generate tool path. This needs to define the tool radius and radius of curvature in addition to the cutting direction whether clockwise or counter clockwise. In addition many other factors had been considered in the machining process of the proposed surface to find the best tool path and G-code. Side step, feed rate and cutting speed had been studied as machining factors affecting tool path generation process. Artificial Neural Network technique had also been considered to find the best tool path depending on the cutting parameters proposed while surface roughness was the characteristic that the tool path process and G-code generation depend on. The impact of the machining parameters on the surface roughness was determined by the use of analysis of variance (ANOVA) that detects more influence for side step (85%, 53%, and 67%).From this study, it has been learned that less side step (0.2) mm and feed speed (1000) mm/min and high value for cutting speed (94.2) m/mingive better tool path to be used in machining operations. This study would help engineers and machinists to select the best tool path for their products.

Enhancement of surface properties for C11000 and 6063Al alloys by using laser shock wave process

Abdulhadi kadhim; Ayad Z.Mohammed; Haitham T.Hussein

Engineering and Technology Journal, 2015, Volume 33, Issue 7, Pages 1211-1219

The use of a laser to modified the surfaces of various materials engineering is a important topics in the present time. Two types of alloys were used in this investigation; 6063Al and C11000 alloys. Samples were prepared by cutting into disc shape of radius 12 mm and then cleaning and polishing process to produce same surface roughness for all samples . Surface roughness and micro hardness were measured for all samples before and after laser shock wave treatment . different laser parameters effect on alloys surface properties were studied such as laser energy , confinement layer( different depth of DDDW) ,and number of laser pulses . The results reveal that the surface roughness are increased by 200% for 6063Al alloy and by 120% for C11000 alloy when we used laser energy of 400mj , number of laser pulses of 100 and confinement layer 5mm . While the microhardness increase by 80% for the two kinds of alloys and at the same conditions . Different measurements were carried out for all samples such as XRF, EDX, SEM , and different mechanical tests For precise and accurate results.

Surface Structure Improvement of Mild Steel and Aluminium by Roller Burnishing

Majeed N; mat

Engineering and Technology Journal, 2015, Volume 33, Issue 5, Pages 1178-1188

In an experimental analysis study, a mix of burnishing parameters was varied to obtain the optimum roller conditions that produce superlative surface smoothness and hardness. The analysis was undertaken on roller burnished mild steel and aluminium using a purpose designed and manufactured tool. The effects of burnishing parameters on both the surface roughness and hardness of mild steel and aluminium work pieces materials were observed and analysed. The parameters included; burnishing speed, feed, force and the number of the tool passes.The results indicated that,depending on the work piece material, surface finishand hardness improvements of around (75%) and (50%) respectively were obtainable at optimumvalues of the mentioned parameters.

Effects of Welding Position, Heat Treatments, and Surface Roughness on the Fatigue Behavior of Welded Aluminum Alloys Using Friction Stir Welding

Shaker Sakran Hassan; Sadeq Hussein Bakhy; Athraa Ali Jawad

Engineering and Technology Journal, 2014, Volume 32, Issue 11, Pages 2773-2787

The present work is aimed to study the fatigue behavior of friction stir welding for the similar and dissimilar joints taking into account the effects of welding position, post welding heat treatments, and surface roughness. The materials were used AA2024T3 and AA6061T6. The maximum welding efficiency achieved at friction stir welding process was 62.8 % of the base metal for the similar 2024-T3 joint, and this value was improved by using post welding heat treatments and reach to 67.9%. Results showed that fatigue strength at 106 cycles depended strongly on welding line position where for welding line at a distance 0.35L from loading side, the reduction in fatigue limit with respect to 2024T3 base material was 45% for similar joint and 58% for dissimilar joints, and for welding line at a distance 0.7 L, the reduction in fatigue strength was 56% for similar joint and 67% for dissimilar joints. While, it was a large reduction in the fatigue strength reaching to 70% in both similar and dissimilar joint for the welding joint at a distance L (i.e at the fixing end). The heat treatments improved the fatigue strength about 31% more than non heat treatments of the similar 2024T3 joint by fsw at 0.7L in high cycle regime. Finally, the non-finishing samples showed a reduction in fatigue strength reaching to 10% more than the finishing samples of the similar 2024T3 joint at 0.7L.

Prediction the Effect of Cutting Parameters on Surface Roughness Using Taguchi Method

Laith A. Mohammed; Ahmed A. Duroobi

Engineering and Technology Journal, 2013, Volume 31, Issue 17, Pages 3334-3342

In this study, the prediction of surface roughness of milled surfaces was carried out
using Taguchi Method with four inputs, namely, cutting direction, stepover, feed per
tooth and workpiece surface geometry. A systematic approach to obtain an optimal
surface roughness was employed to consider the effects of Taguchi method for this
application using CNC milling machine with ball mill cutter. The results show that the
Taguchi method is an effective tool in predicting the optimum factors to obtain
minimum surface roughness, which are stepover, surface type, feed per tooth and
cutting direction respectively.