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Optimisation of variation coolant system techniques in machining aluminium alloy Al319

Zainal Ariffin S., Efendee A. M., Redhwan A. A. M., Alias M., Arifuddin A., Kamrol Amri M., Mohd Ali M., Khalil K., Aminullah A. R. M., Hasnain A. R., Baba N. B.

Journal of Achievements in Materials and Manufacturing Engineering

2022

Vol. 113, nr 2

72--77

Purpose: Cutting parameters are often chosen for machining by machine operators in the industry. The experience and efficiency of the machine operator in producing a quality product are frequently used to decide parameter selection - low productivity results from improper parameter selection, inefficient machining, and technological issues. Today's key issues in the machining industry are focusing on increasing machining performance on surface roughness while minimising coolant usage. The study's objective is to enhance the performance of the nozzle lubrication system during the turning operation of an aluminium alloy 319 workpieces (Al319) to generate good surface roughness by applying turning parameters such as cutting speed, feed rate, and the depth of cut. Design/methodology/approach: Response Surface Method (RSM) was used to create the experimental method for this investigation, carried out using a CNC lathe machine with two axial movements and a wet cooling nozzle with a size of 1.0 mm. Synthetic soluble lubricants, Al2O3-coated cemented carbide inserts, and Aluminium alloy 319 were utilised as cutting tools and workpiece materials. Findings: To study the influence of cutting parameters on surface roughness, the Analysis of Variance (ANOVA) approach was utilised while the response surface method was performed to achieve an optimum machining performance (RSM). When comparing dry and wet cooling systems, the size of 1.0 mm nozzle shows appropriate surface roughness. According to the ANOVA analysis, the key factor impacting the surface roughness as machining performance in lubrication technique experiments was the utilisation of 1.0 mm nozzle size. Research limitations/implications: The findings of combination machining parameters at a cutting speed of 270 m/min and a cutting depth of 0.60 mm at a feed rate of 0.08 mm/min offered the best results, achieving a surface roughness, Ra of 0.94 μm. Practical implications: The use of coolant size nozzle 1.0 mm technology combined with the use of correct machining parameters can improve machining cuts. Originality/value: The novel size of 1.0 mm nozzle in this current research is also valuable for reducing and increasing productivity in the machining business, as well as reducing dependency on machining operators' experience and abilities.

Comparative investigations of cutting process of nodular cast iron with carbide and ceramic tools

Grzesik W., Żak K.

Archiwum Technologii Maszyn i Automatyzacji

2011

Vol. 31, nr 2

27-36

This paper presents the results of comparative investigations in case of turning of the pearlitic--ferritic nodular cast iron (NCI) using CVD-TiC/Ti(C,N)/Al20,/TiN coated carbide and silicon nitride ceramic tools. The process outputs were the cutting and feed forces, cutting temperature, friction and tool wear. Based on the experimental results obtained for these two cutting tool materials, some important differences in the process performance are revealed. During cutting tests performed the cutting speed was changed between 160 and 320 m/min and feed rate was varied between 0.04 and 0.28 mm/rev.

W artykule zaprezentowano wyniki porównawczych badań procesu skrawania żeliwa sfero-idalnego o strukturze perlityczno-ferrytycznej narzędziami z węglika spiekanego z powłoką TiC/Ti(C,N)/Al203/TiN oraz z ceramiki azotkowej Si3N4. Mierzono siłę skrawania i siłę posuwową, temperaturę skrawania, współczynnik tarcia i zużycie ostrza narzędzia. Przeanalizowano niektóre znaczące różnice w przebiegu skrawania badanymi narzędziami. Próby prowadzono ze zmienną prędkością skrawania (między 160 i 320 m/min) i zmiennym posuwem (0,04 i 0,28 mm/obr).