In recent years, mold manufacturers have had to meet growing demand for high precision molds, low cost and short delivery time due to the miniaturization of finished products, price competition with overseas companies, and reduced model cycles. In line with these market changes, users have been gradually inclined to shift their machining methods applied to key mold parts (made of hardened steel...

This paper presents the suitable depth of cut, spindle speed and feed rate that will be chosen during machining. If thus parameters are not considered, this can provoke abnormal tool behavior such as chatter. Chatter will limit the tool life which only can be use for just a few times. To predict the chatter occurs, the parameters will be use are spindle speed, depth of cut and feed rate. CNC ma...

Surface finish is one of the prime requirements of customers for machined parts. The present paper presents an experimental study to investigate the effects of cutting parameters like spindle speed, feed and depth of cut on surface finish and material removal rate on EN-8. Taguchi methodology has been applied to optimize cutting parameters. The results showed that the spindle speed (the most si...

In todays manufacturing industry, high-speed milling plays an important role. The main benefits of high-speed milling over conventional milling are the high material removal rates with relatively low cutting forces. The efficiency of high-speed milling is limited by the occurrence of regenerative chatter. Chatter is an undesired instability phenomenon, causing excessive tool vibrations, reduced...

This paper presents a methodology to determine simultaneously (a) the flow stress at high deformation rates and temperatures that are encountered in the cutting zone, and (b) the friction at the chip–tool interface. This information is necessary to simulate high-speed machining using FEM based programs. A flow stress model based on process dependent parameters such as strain, strain-rate and te...

High-speed machining offers several advantages such as increased flexibility and productivity for discrete-part manufacturing. However, excessive heat generation and resulting high temperatures on the tool and workpiece surfaces in high-speed machining leads to a shorter tool life and poor part quality, especially if the tool edge geometry and cutting conditions were not selected properly. In t...

A numerical model is developed to simulate the process of oxygen-assisted laser cutting of mild steels. The coupled concentration and energy balance equations are solved by a control-volume based computational scheme while the velocity field is obtained by the analytical boundary theory. The enthalpy method is adopted to trace the free boundary of phase change. The steady-state simulation resul...

In this paper, an attempt has been made to experimental investigation the machinability of aluminum metal matrix composite (LM13/SiC/15p) during continuous turning of composite rods using carbide inserts. Base matrix material is Aluminium LM13 reinforced with 15 % weight by volume of Silicon carbide particles of mean diameter 20 μm to 40 μm is used. The main focus of investigation is to determi...

We examined the effects of air pressure on the free-running speed of air-bearing and torque-type ball-bearing air-turbine handpieces. The air pressure for the former should be kept at a certain high level to maintain the stable super-thin air-bearing film and to provide the quasi-constant speed of around 420,000 to 480,000 rpm. On the other hand, the air pressure for the latter could be adjuste...

WEDM process is used extensively where the conventional machining process shows their limitations. Wire Electrical Discharge Machining is used to manufacture geometrically intricate shapes with higher accuracy and better surface finish. In the present study, the performance parameters i.e. cutting speed and surface roughness were investigated. The experiments were conducted under the constant c...