MECH ENG 2020 Materials And Manufacturing

MECH ENG 2020 Materials And Manufacturing

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MECH ENG 2020 Materials And Manufacturing

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MECH ENG 2020 Materials And Manufacturing

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Course Code: MECHENG2020
University: The University Of Adelaide

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Country: Australia

Question:
This reflection includes everything that is considered important to the students such as how this task helped him/her in better understanding lecture materials and/or ways of improvement in conducting the tasks considering the laminations and possibilities and so on.
Answer:
Introduction:

This exercise made it clear to me that reducing the cutting speed of the machine tends to increase the surface roughness due to the impact of built up edge on the surface of the specimen. This is because the low cutting speeds prevent the occurrence of the built up edge during the milling process which generates a large burr quantity on the machined surface. The impact of this is improving the surface roughness and thus the quality of the surface finish of the specimen being milled. The machine used to mill the specimen through increasing the cutting speed thus leads to the advantages of surface roughness such as reduced loss of material, high tensile strength, precision and high production rates. The cutting speed ought to be low in order to create groves on the surface of the material, which contribute to surface roughness required for the different advantageous benefits of machining in enhancing the corrosion resistance, strength and resistance to creep (Özel, Hsu, & Zeren, 2005).
Further I became aware that ensuring that the feeding rate remains high guarantees that the cutting forces and the residual stresses from milling processes increases the dynamic stability of the surface being milled thus increasing the surface roughness of the specimen. (Benardos & Vosniakos, 2003). The feed rate refers to the speed at which the tool of milling machine advances along its own cutting path to interact with the specimen being milled (Asiltürk & Akku?, 2011). Milling allows the specimen to have a more applicable desired shape contributing to a good quality of surface finishing due to the high feed rate thus a reduction in the costs of metal parts manufacturing in terms of the sizing tolerances that may be required for high precision machining.  This high feed rate also improves the benefits of a high surface roughness through the reduction of machining time and costs as well as guaranteeing the fatigue strength corrosion resistance and creep life of the part is guaranteed. (Korkut & Donertas, 2007) Thus the feed rate affects the surface roughness in that it controls the amount of material being taken off of the specimen being machined. As such the feed rate ought to be kept at a high rate in order to allow the tool to have ample time with the surface of the specimen in order to produce a good quality surface roughness
The study was able to establish that having a small feed rate and a high cutting speeds produces the best quality of surface roughness during cold forging machining. This is demonstrated in the results through comparing the surface roughness of the aluminum specimen to the milling tool’s cutting speed at a high and a low feeding rate. Results demonstrated that when the feed rate is at 180mm/min, the surface roughness increased at a negligible rate but began to decrease at high cutting speeds. The highest roughness of 0.27 is noted at the lowest cutting speed. This is the opposite in the case of the higher feed rate of 771mm/min where a higher cutting speed is seen to cause a low surface roughness and the highest roughness coefficient achieved was 0.83. This therefore implies that the surface roughness decreased as the cutting speed increases as has been demonstrated in the findings of both the graphs. The impact of feed rate is also noted to have an impact on the surface roughness of the specimen, because the values of highest roughness was lower in the test run with a lower feed rate than the test run with the higher feed rate. This therefore emphasizes that a high feed rate implies an increase in the surface roughness important for the quality of the specimens and the costs of manufacturing in terms of reduction of time and costs of operations. The quality of the specimen is enhanced in strength, creep, and resistance to corrosion (Korkut & Donertas, 2007).
References
Asiltürk, I., & Akku?, H. (2011). Determining the effect of cutting parameters on surface roughness in hard turning using the Taguchi method. Measurement, 44(9), 1697-1704.
Benardos, P. G., & Vosniakos, G. C. (2003). Predicting surface roughness in machining: a review. International journal of machine tools and manufacture, 43(8), 833-844.
Korkut, I., & Donertas, M. A. (2007). The influence of feed rate and cutting speed on the cutting forces, surface roughness and tool–chip contact length during face milling. Materials & design, 28(1), 308-312.
Özel, T., Hsu, T. K., & Zeren, E. (2005). Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel. The International Journal of Advanced Manufacturing Technology, 25(3-4), 262-269.

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