Dry Machining

Dry machining is a machining process with out coolant, and it has become more popular as a finishing process. Thus, it is especially crucial to select the machining parameters to obtain the desired surface finish of machined component. In the present investigation, the influence of process parameters like speed, feed and depth of cut in dry-machining, are studied as surface roughness as the output response variable. The concept of Design of Experiments (DOE) was used for necessary experimentation. En31 bearing steel material was considered in the present study. The experimental results were analyzed statistically to study the influence of process parameters on surface roughness.

Perhitungan biaya pemesinan merupakan faktor paling penting dalam pembuatan produk. Biaya pemesinan untuk setiap peralatan mesin sering diperkirakan dari total biaya pabrik sesuai dengan metode konvensional yang digunakan untuk manajemen industri. Total pendapatan dan pengeluaran pabrik dapat diperoleh, namun status operasi peralatan mesin berbeda. Hal ini dapat dikatakan bahwa biaya pemesinan yang akurat untuk setiap bagian tidak dapat diperkirakan secara nyata. Oleh karena itu kajian perhitungan biaya pembubutan Baja AISI 4340 dengan menggunakan mata pahat keramik perlu dilakukan untuk mengetahui biaya permesinan yang diperlukan dalam suatu produksi pemotongan logam.Pada penelitian ini mata pahat keramik di variasikan terhadap rake angle,hal ini bertujuan untuk mengetahui besaran gaya dan daya potong serta dihubungkan dengan umur pahat dan waktu pemesinan. Data-data tersebut kemudian disubtitusikan kedalam persamaan biaya permesinan perkomponen. Lima variasi sudut potong mata pahat (rake angle) digunakan untuk menganalisa pengaruhnya terhadap proses permesinan. Pada proses permesinan logam menggunakan variasi rake angle memberi pengaruh terhadap panjang permesinan yang terjadi, dimana rake angle positif menghasilkan batas nilai keausan mata pahat (VB) yang ditetapkan lebih lama dibandingkan dengan rake angle lainnya. Waktu permesinan dan panjang pemotongan memberi pengaruh yang berarti terhadap perhitungan biaya permesinan perkomponen. Pada rake angle +3o dan + 6o, nilai keausan mata pahat dicapai pada waktu 26 menit, panjang pemotongan yang dihasilkan adalah sebesar 2600 mm dan biaya pemesinan sebesar Rp 21534/komponen.

Kata kunci : Alloy steel, biaya pemesinan, mesin bubut cnc, mata pahat keramik, mata pahat karbida

This paper reports the optimization of process parameters such as cutting speed (m/min), feed (mm/rev), depth of cut(mm) and nose radius (mm) in Dry and Wet machining using Taguchi method. Cutting fluids in machining operations help to remove the heat generated during cutting, to achieve better tool life and surface finish and to facilitate the flushing of chips. The machining without the use of any cutting fluid is becoming increasingly important due to concern regarding safety and environmental legalization. In addition it reduce 17% of manufacturing costs by not using cutting fluids. However in Dry machining operations, the friction and adhesion between chip and tool tend to be higher, which causes higher temperatures, higher wear rates and shorter tool life . This problem can overcome by using PVD coated TiAlN cutting tool. PVD -TiAlN coated carbide tools are used frequently in metal cutting process due to the higher hardness, wear resistance and chemical stability. In addition it improves tool life and machining performance.

Nowadays, aluminum alloy 7075-T6 has received a high demand in the automotive industry due to its advantages in the aerospace industry, which possessing exceptional mechanical combinations and chemical elements such as high tensile strength, high strength, high corrosion resistance, zinc, magnesium, and copper to increase their strength. Nevertheless, environmentally friendly approaches are necessary to improvise surface quality and machining performances as well as minimize the adverse environment. This has directly influenced the trend of approach or strategy of cutting fluids towards the machining of high-performance material in the automotive industry. There have been some probations to decrease the volume of cutting fluid application in machining. The approach of cutting fluids become prominent indicator in contribution to minimize the application of cutting fluid so that the machining of aluminum alloy 7075-T6 become more effective and environmental friendly. Thus, results can be found in the low tool wear, minimum heat energy generated and reduced machining cost in encouraging the application of MQL as viable formulations to enhance the machining performance and machined surface quality. The primary objective of review work is summarized all the emerging environmentally friendly approaches towards the high-performance material. Impact of machining process parameters on dependent variables such as surface integrity, tool wear, chip formation, and mechanical properties have been discussed in the light of the findings of the recent study.

The temperature generated by friction and plastic deformation in the secondary shear zone strongly controls tool wear. At lower cutting speeds tool wear is not severe insofar as the temperature is not significant. When the cutting speed is increased, there is a transition in wear mechanisms from abrasion and/or adhesion to diffusion. In the present paper, the change in wear mechanisms as a function of cutting speed and coating material is discussed. The cutting tests were performed on a rigid instrumented drilling bench without the use of cutting fluids. AA2024 aluminium alloy was used to investigate the wear mechanisms of cemented tungsten carbide and HSS tools. Three cutting speeds (25, 65 and 165 m/min) and a constant feed rate of 0.04 mm/rev were selected for the experiments. The best results in terms of maximum and minimum hole diameter deviations and surface roughness are obtained for the uncoated and coated tungsten carbide drills. The results also show that HSS tool is not suitable for dry machining of AA2024 aluminium alloy. q

Quality is the prime requirement for most of the customers and hence it is always a challenging and upcoming task in industries. This work focus on Surface Roughness produced in hard turning process on Lathe. The process of hard turning is done on AISI 1040 Steel material under dry conditions using coated Carbide Inserts and High Speed Steel (HSS) Tools. Spindle Speed and Feed are chosen as control factors. The control factors are adopted to analyze significance and contribution on the Surface Roughness of the machined parts.
Taguchi methodology based on Orthogonal Arrays (OA) is used to Design the Experiments. Signal-to-noise Ratio (S/N ratio) of the generated Roughness values is used to evaluate the optimal machining parameter combinations. Later Analysis of Variance (ANOVA) is used to analyze the influences and contribution of the machining parameters on the Roughness values based on F-Statistic Test.
Regression Model analysis was developed for predicting the Average Surface Roughness (Ra) as a function of Speed and Feed. Confirmation experiments are yielding an error of max 8.55% and 0.46% in Regression, while machining with Carbide and HSS tools respectively.

This paper investigates the effects of different surface pretreatments on the adhesion and performance of CVD diamond coated WC-Co turning inserts for the dry machining of high silicon aluminum alloys. Different interfacial characteristics between the diamond coatings and the modified WC-Co substrate were obtained by the use of two different chemical etchings and a CrN/Cr interlayer, with the aim to produce an adherent diamond coating by increasing the interlocking effect of the diamond film, and halting the catalytic effect of the cobalt present on the cemented carbide tool. A systematic study is analyzed in terms of the initial cutting tool surface modifications, the deposition and characterization of microcrystalline diamond coatings deposited by HFCVD synthesis, the estimation of the resulting diamond adhesion by Rockwell indentations and Raman spectroscopy, and finally, the evaluation of the dry machining performance of the diamond coated tools on A390 aluminum alloys. The experiments show that chemical etching methods exceed the effect of the CrN/Cr interlayer in increasing the diamond coating adhesion under dry cutting operations. This work provided new insights about optimizing the surface characteristics of cemented carbides to produce adherent diamond coatings in the dry cutting manufacturing chain of high silicon aluminum alloys.

Quality is the prime requirement for most of the customers and hence it is always a challenging and upcoming task in industries. This work focus on Surface Roughness produced in hard turning process on Lathe. The process of hard turning is done on AISI 1040 Steel material under dry conditions using coated Carbide Inserts and High Speed Steel (HSS) Tools. Spindle Speed and Feed are chosen as control factors. The control factors are adopted to analyze significance and contribution on the Surface Roughness of the machined parts. Taguchi methodology based on Orthogonal Arrays (OA) is used to Design the Experiments. Signal-to-noise Ratio (S/N ratio) of the generated Roughness values is used to evaluate the optimal machining parameter combinations. Later Analysis of Variance (ANOVA) is used to analyze the influences and contribution of the machining parameters on the Roughness values based on F-Statistic Test. Regression Model analysis was developed for predicting the Average Surface Roug...

This paper investigates the effects of different surface pretreatments on the adhesion and performance of CVD diamond coated WC-Co turning inserts for the dry machining of high silicon aluminum alloys. Different interfacial characteristics between the diamond coatings and the modified WC-Co substrate were obtained by the use of two different chemical etchings and a CrN/Cr interlayer, with the aim to produce an adherent diamond coating by increasing the interlocking effect of the diamond film, and halting the catalytic effect of the cobalt present on the cemented carbide tool. A systematic study is analyzed in terms of the initial cutting tool surface modifications, the deposition and characterization of microcrystalline diamond coatings deposited by HFCVD synthesis, the estimation of the resulting diamond adhesion by Rockwell indentations and Raman spectroscopy, and finally, the evaluation of the dry machining performance of the diamond coated tools on A390 aluminum alloys. The experiments show that chemical etching methods exceed the effect of the CrN/Cr interlayer in increasing the diamond coating adhesion under dry cutting operations. This work provided new insights about optimizing the surface characteristics of cemented carbides to produce adherent diamond coatings in the dry cutting manufacturing chain of high silicon aluminum alloys.

With growing attention being given to environmental and health hazards in machining, an eco-friendly method is a crucial need. In this study experiments were conducted to evaluate the effects of cutting conditions in drilling of Metal Matrix Composites (MMCs) where cutting speed, feed, SiC volume fraction were selected as process parameters while surface roughness and circularity as responses during high speed drilling of MMCs. The findings revealed that the cutting condition has a significant effect on surface roughness and circularity. The best results for the circularity were achieved in dry drilling, however, in terms of surface roughness it gives almost similar results. This experimental study reveals that dry cutting condition can be used in industrial application like drilling, especially in machining of MMCs, to avoid unnecessary application of metal working fluid and, consequently, their negative impact on the environment

Customary mineral based liquids are as a rule broadly utilized in cooling and greases in machining activities. Nonetheless, these cutting liquids are the suitable wellspring of numerous natural and organic issues. To kill the evil impacts related with cutting liquids, it is important to move towards practical machining methods. Such sustainable machining techniques utilize minimize the amount of cutting liquid, fluid nitrogen, vegetable oil or packed air as a cooling-oil medium. The liquids utilized in economical machining strategies are viewed as absolutely biodegradable and Eco-friendly. This paper is a careful survey of the relative multitude of current environmental friendly machining methods as of now rehearsed in the metal cutting cycle. It has been likewise discovered that these economical machining strategies more often than not give better outcomes as far as improved surface nature of the machined part, upgraded apparatus life, less cutting temperatures and slicing powers when contrasted with traditional wet machining techniques. The principle motivation behind this survey work is to recognize the diverse supportable strategies and empower the utilization of such procedures in metal machining, so that, the reducing interaction turns out to be more expense powerful and climate inviting.

This paper reports the optimization of process parameters such as cutting speed (m/min), feed (mm/rev), depth of cut(mm) and nose radius (mm) in Dry and Wet machining using Taguchi method. Cutting fluids in machining operations help to remove the heat generated during cutting, to achieve better tool life and surface finish and to facilitate the flushing of chips. The machining without the use of any cutting fluid is becoming increasingly important due to concern regarding safety and environmental legalization. In addition it reduce 17% of manufacturing costs by not using cutting fluids. However in Dry machining operations, the friction and adhesion between chip and tool tend to be higher, which causes higher temperatures, higher wear rates and shorter tool life. This problem can overcome by using PVD coated TiAlN cutting tool. PVD-TiAlN coated carbide tools are used frequently in metal cutting process due to the higher hardness, wear resistance and chemical stability. In addition it improves tool life and machining performance. The work piece material is Ti-6Al-4V ELI which is most widely used in bio-medical applications due to its high strength to weight ratio and exceptional corrosion resistance. The cost of titanium still remain high cost but longer service life counter balance the production cost. If the work piece material is machined by Dry machining the production cost will be reduced further without affecting the quality parameters .Experiment was conducted on Dry and Wet machining with identical cutting parameters. The main output monitored was the surface roughness.

The research aimed to evaluate the performance of neem seed oil as a cutting fluid in orthogonal machining of aluminium-manganese alloy 3003, carbide cutting tool insert was used as a cutting tool under different machining parameters of spindle speed, feed rate and depth of cut with different types of cutting fluids (neem seed oil and soluble oil) as well as dry machining. The results were obtained in terms of the average surface roughness of the machined workpiece and flank wear under different cutting parameters (spindle speed, feed rate and depth of cut). The results indicated that the neem seed oil cutting fluid reduced the surface roughness by 39% and 22% as compared to dry turning and soluble oil cutting respectively. It was established from the results that the neem seed oil cutting fluid reduced the flank wear by 72% and 56% as compared to dry turning and soluble oil cutting respectively. Based on the study, it can be concluded that neem seed oil cutting fluid facilitates a ...

Near-dry wire electrical discharge machining is a modified WEDM process, has no adverse effects on the environment, in which metal removals have been done with the dielectric medium being used in the form of a mist. As the increase in production by reducing the machining time is a costly affair, the input parameters attract considerable thought in optimizing them. The predominant control characteristics in this study are the time-bound material removal and surface quality. The time duration of the electrical pulse on and off, Wire Feed, Air inlet pressure, and Water flow rate are the parameters considered for this experimental analysis. In this paper, the optimization techniques such as RSM method and ANOVA were used to route the experiments and optimize the responses of near-dry WEDM process for machining the material Monel alloy. A model has been formulated mathematically for the two vital responses needed, under the influence of regression analysis. Additivity test has been performed to validate the mathematical model. The air-water mixture in the form of a mist was used in place of dielectric medium to study the impact on MRR, Ra, and Environment. It was observed that a high Surface finish could be obtained at 3 bar pressure.

This paper investigates the effects of different surface pretreatments on the adhesion and performance
of CVD diamond coated WC–Co turning inserts for the dry machining of high silicon aluminum alloys.
Different interfacial characteristics between the diamond coatings and the modified WC–Co substrate
were obtained by the use of two different chemical etchings and a CrN/Cr interlayer, with the aim to
produce an adherent diamond coating by increasing the interlocking effect of the diamond film, and
halting the catalytic effect of the cobalt present on the cemented carbide tool. A systematic study is
analyzed in terms of the initial cutting tool surface modifications, the deposition and characterization
of microcrystalline diamond coatings deposited by HFCVD synthesis, the estimation of the resulting
diamond adhesion by Rockwell indentations and Raman spectroscopy, and finally, the evaluation of the
dry machining performance of the diamond coated tools on A390 aluminum alloys. The experiments
show that chemical etching methods exceed the effect of the CrN/Cr interlayer in increasing the diamond
coating adhesion under dry cutting operations. This work provided new insights about optimizing the
surface characteristics of cemented carbides to produce adherent diamond coatings in the dry cutting
manufacturing chain of high silicon aluminum alloys.

The research aimed to evaluate the performance of neem seed oil as a cutting fluid in orthogonal machining of aluminium-manganese alloy 3003, carbide cutting tool insert was used as a cutting tool under different machining parameters of spindle speed, feed rate and depth of cut with different types of cutting fluids (neem seed oil and soluble oil) as well as dry machining. The results were obtained in terms of the average surface roughness of the machined workpiece and flank wear under different cutting parameters (spindle speed, feed rate and depth of cut). The results indicated that the neem seed oil cutting fluid reduced the surface roughness by 39% and 22% as compared to dry turning and soluble oil cutting respectively. It was established from the results that the neem seed oil cutting fluid reduced the flank wear by 72% and 56% as compared to dry turning and soluble oil cutting respectively. Based on the study, it can be concluded that neem seed oil cutting fluid facilitates a ...