Surface Finish Comparison of Dry and Coolant Fluid High-Speed Milling of JIS SDK61 Mould Steel

Authors

  • T. H. Le Faculty of Mechanical Engineering, Hanoi Vocational College of High Technology, Vietnam
  • V. B. Pham Faculty of Mechanical Engineering, Hanoi University of Industry, Vietnam
  • T. D. Hoang Faculty of Mechanical Engineering, Hanoi University of Industry, Vietnam https://orcid.org/0000-0003-3543-7539
Volume: 12 | Issue: 1 | Pages: 8023-8028 | February 2022 | https://doi.org/10.48084/etasr.4594

Abstract

This paper investigates the influence of dry high-speed milling on the surface quality of JIS SKD61 hard steel, compared to the conventional coolant fluid method. This research was conducted in a Super MC 500 high-speed CNC milling machine with a Hitachi coated carbide 20mm in diameter. High-speed cutting parameters such as cutting speed V, cutting depth t, and spindle speed S were considered as variants. The experiment was designed based on Taguchi's L9. Surface quality, including Ra and Rq, was measured using the Mitutoyo Surftest SV-210. A mathematical regression model was found for the average values of surface roughness through regression analysis for dry and coolant fluid conditions. The chosen high-speed milling parameters and the respective Ra and Rq values were obtained by ANOVA. The grey relation scores for wet and dry milling surface quality for cut depth, feed rate, and cutting speed were 0.7527, 0.7869, 0.6302, and 0.8167, 0.7199, 0.6040, respectively. The results showed that the feed rate had the greatest influence on the surface quality during the high-speed coolant milling of hardened steel, while the depth of the cut had the greatest influence on the surface quality during the high-speed dry milling process.

Keywords:

SKD61, FGRA, surface roughness, high-speed milling

Downloads

Download data is not yet available.

References

B. T. Daymond, N. Binot, M. L. Schmidt, S. Preston, R. Collins, and A. Shepherd, "Development of Custom 465® Corrosion-Resisting Steel for Landing Gear Applications," Journal of Materials Engineering and Performance, vol. 25, no. 4, pp. 1539–1553, Apr. 2016. DOI: https://doi.org/10.1007/s11665-015-1830-5

K. J, P. V, K. V, and G. Priyadharshini B, "Multi response optimization of process parameters using grey relational analysis for milling of hardened Custom 465 steel," Procedia Manufacturing, vol. 30, pp. 451–458, Jan. 2019. DOI: https://doi.org/10.1016/j.promfg.2019.02.064

D. H. Tien, Q. T. Duc, T. N. Van, N.-T. Nguyen, T. Do Duc, and T. N. Duy, "Online monitoring and multi-objective optimisation of technological parameters in high-speed milling process," The International Journal of Advanced Manufacturing Technology, vol. 112, no. 9, pp. 2461–2483, Feb. 2021. DOI: https://doi.org/10.1007/s00170-020-06444-x

C. Wang, Y. Xie, L. Zheng, Z. Qin, D. Tang, and Y. Song, "Research on the Chip Formation Mechanism during the high-speed milling of hardened steel," International Journal of Machine Tools and Manufacture, vol. 79, pp. 31–48, Apr. 2014. DOI: https://doi.org/10.1016/j.ijmachtools.2014.01.002

T. D. Hoang, N.-T. Nguyen, D. Q. Tran, and V. T. Nguyen, "Cutting Forces and Surface Roughness in Face-Milling of SKD61 Hard Steel.," Strojniski Vestnik - Journal of Mechanical Engineering, vol. 65, no. 6, pp. 375–386, Jun. 2019. DOI: https://doi.org/10.5545/sv-jme.2019.6057

S. Kalpakjian and S. Schmid, Manufacturing Engineering & Technology, 7th edition. Upper Saddle River, NJ, USA: Pearson, 2013.

J. Haider and M. S. J. Hashmi, "Health and Environmental Impacts in Metal Machining Processes," in Comprehensive Materials Processing, S. Hashmi, G. F. Batalha, C. J. Van Tyne, and B. Yilbas, Eds. Oxford, UK: Elsevier, 2014, pp. 7–33. DOI: https://doi.org/10.1016/B978-0-08-096532-1.00804-9

A. W. El-Morsy, "Wear Analysis of a Ti-5Al-3V-2.5Fe Alloy Using a Factorial Design Approach and Fractal Geometry," Engineering, Technology & Applied Science Research, vol. 8, no. 1, pp. 2379–2384, Feb. 2018. DOI: https://doi.org/10.48084/etasr.1743

L. Lu et al., "Microstructure and cutting performance of CrTiAlN coating for high-speed dry milling," Transactions of Nonferrous Metals Society of China, vol. 24, no. 6, pp. 1800–1806, Jun. 2014. DOI: https://doi.org/10.1016/S1003-6326(14)63256-8

T.-T. Nguyen, "Prediction and optimization of machining energy, surface roughness, and production rate in SKD61 milling," Measurement, vol. 136, pp. 525–544, Mar. 2019. DOI: https://doi.org/10.1016/j.measurement.2019.01.009

E. Vazquez, J. Gomar, J. Ciurana, and C. A. Rodríguez, "Analyzing effects of cooling and lubrication conditions in micromilling of Ti6Al4V," Journal of Cleaner Production, vol. 87, pp. 906–913, Jan. 2015. DOI: https://doi.org/10.1016/j.jclepro.2014.10.016

S. Singh, "Optimization of machining characteristics in electric discharge machining of 6061Al/Al2O3p/20P composites by grey relational analysis," The International Journal of Advanced Manufacturing Technology, vol. 63, no. 9, pp. 1191–1202, Dec. 2012. DOI: https://doi.org/10.1007/s00170-012-3984-8

Z. Li, W. Ding, C. Liu, and H. Su, "Prediction of grinding temperature of PTMCs based on the varied coefficients of friction in conventional-speed and high-speed surface grinding," The International Journal of Advanced Manufacturing Technology, vol. 90, no. 5, pp. 2335–2344, May 2017. DOI: https://doi.org/10.1007/s00170-016-9578-0

D. Nguyen, J. Wu, N. M. Quang, L. A. Duc, and P. X. Son, "Applying fuzzy grey relationship analysis and Taguchi method in polishing surfaces of magnetic materials by using magnetorheological fluid," The International Journal of Advanced Manufacturing Technology, vol. 112, no. 5, pp. 1675–1689, Jan. 2021. DOI: https://doi.org/10.1007/s00170-020-06567-1

R. S. Pawade and S. S. Joshi, "Multi-objective optimization of surface roughness and cutting forces in high-speed turning of Inconel 718 using Taguchi grey relational analysis (TGRA)," The International Journal of Advanced Manufacturing Technology, vol. 56, no. 1, pp. 47–62, Sep. 2011. DOI: https://doi.org/10.1007/s00170-011-3183-z

H. Zhou, W.-F. Ding, Z. Li, and H.-H. Su, "Predicting the grinding force of titanium matrix composites using the genetic algorithm optimizing back-propagation neural network model," Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 233, no. 4, pp. 1157–1167, Mar. 2019. DOI: https://doi.org/10.1177/0954405418780166

A. Kadier, P. Abdeshahian, Y. Simayi, M. Ismail, A. A. Hamid, and M. S. Kalil, "Grey relational analysis for comparative assessment of different cathode materials in microbial electrolysis cells," Energy, vol. 90, pp. 1556–1562, Oct. 2015. DOI: https://doi.org/10.1016/j.energy.2015.06.108

N. Duy Trinh, N. Nhat Tan, N. M. Quang, P. Thi Thieu Thoa, and L. A. Duc, "Application of magnetic liquid slurries and fuzzy grey analysis in polishing nickel-phosphorus coated SKD11 steel," Particulate Science and Technology, pp. 1–14, Jul. 2021. DOI: https://doi.org/10.1080/02726351.2021.1948471

V. C. Nguyen, T. D. Nguyen, and D. H. Tien, "Cutting Parameter Optimization in Finishing Milling of Ti-6Al-4V Titanium Alloy under MQL Condition using TOPSIS and ANOVA Analysis," Engineering, Technology & Applied Science Research, vol. 11, no. 1, pp. 6775–6780, Feb. 2021. DOI: https://doi.org/10.48084/etasr.4015

F. Siddiqui, M. A. Akhund, A. H. Memon, A. R. Khoso, and H. U. Imad, “Health and Safety Issues of Industry Workmen,” Engineering, Technology & Applied Science Research, vol. 8, no. 4, pp. 3184–3188, Aug. 2018. DOI: https://doi.org/10.48084/etasr.2138

Downloads

How to Cite

[1]
T. H. Le, V. B. Pham, and T. D. Hoang, “Surface Finish Comparison of Dry and Coolant Fluid High-Speed Milling of JIS SDK61 Mould Steel”, Eng. Technol. Appl. Sci. Res., vol. 12, no. 1, pp. 8023–8028, Feb. 2022.

Metrics

Abstract Views: 283
PDF Downloads: 201

Metrics Information
Bookmark and Share