Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C)

Problem statement: Chip shape and size varied widely in machining operations. Undesirable chip formation had a detrimental effect on surface finish, work-piece accuracy, chatter and tool life. Approach: This study included the findings of an experimental study on the instabilities of the chip format...

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Main Authors:	Patwari, Muhammed Anayet Ullah, Amin, A. K. M. Nurul, Faris, Waleed Fekry
Format:	Article
Language:	English
Published:	Science Publications 2010
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://irep.iium.edu.my/16686/ http://irep.iium.edu.my/16686/ http://irep.iium.edu.my/16686/ http://irep.iium.edu.my/16686/1/ajeas31193-200%5B1%5D.pdf

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spelling	iium-166862012-01-26T00:51:18Z http://irep.iium.edu.my/16686/ Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C) Patwari, Muhammed Anayet Ullah Amin, A. K. M. Nurul Faris, Waleed Fekry TJ Mechanical engineering and machinery Problem statement: Chip shape and size varied widely in machining operations. Undesirable chip formation had a detrimental effect on surface finish, work-piece accuracy, chatter and tool life. Approach: This study included the findings of an experimental study on the instabilities of the chip formation and development of a mathematical model based on statistical approach for the prediction of the instability of chip formation during the machining of medium carbon steel (S45C). Results: It has been identified that the chip formation process has a discrete nature, associated with the periodic shearing process of the chip. Typical instabilities of periodic nature, in the form of primary and secondary saw/serrated teeth, which appear at the main body and free edge of the chip respectively, have been identified. Mechanisms of formation of these teeth have been studied and the frequencies of their formation have been determined under various machining conditions. Small Central composite design was employed in developing the chip serration frequency model in relation to primary cutting parameters by Response Surface Methodology (RSM). Conclusion/Recommendations: The mathematical model for the chip serration frequency has been developed, in terms input cutting parameters (cutting speed, feed and depth of cut) in end milling of S45C steel using TiN inserts under full immersion. The adequacy of the predictive model was verified using ANOVA at 95% confidence level. Science Publications 2010 Article PeerReviewed application/pdf en http://irep.iium.edu.my/16686/1/ajeas31193-200%5B1%5D.pdf Patwari, Muhammed Anayet Ullah and Amin, A. K. M. Nurul and Faris, Waleed Fekry (2010) Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C). American Journal of Applied Sciences , 3 (1). pp. 193-200. ISSN 1554-3641(O), 1546-9239 (P) http://thescipub.com/ajas.toc DOI: 10.3844/ajeassp.2010.193.200
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Patwari, Muhammed Anayet Ullah Amin, A. K. M. Nurul Faris, Waleed Fekry Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C)
description	Problem statement: Chip shape and size varied widely in machining operations. Undesirable chip formation had a detrimental effect on surface finish, work-piece accuracy, chatter and tool life. Approach: This study included the findings of an experimental study on the instabilities of the chip formation and development of a mathematical model based on statistical approach for the prediction of the instability of chip formation during the machining of medium carbon steel (S45C). Results: It has been identified that the chip formation process has a discrete nature, associated with the periodic shearing process of the chip. Typical instabilities of periodic nature, in the form of primary and secondary saw/serrated teeth, which appear at the main body and free edge of the chip respectively, have been identified. Mechanisms of formation of these teeth have been studied and the frequencies of their formation have been determined under various machining conditions. Small Central composite design was employed in developing the chip serration frequency model in relation to primary cutting parameters by Response Surface Methodology (RSM). Conclusion/Recommendations: The mathematical model for the chip serration frequency has been developed, in terms input cutting parameters (cutting speed, feed and depth of cut) in end milling of S45C steel using TiN inserts under full immersion. The adequacy of the predictive model was verified using ANOVA at 95% confidence level.
format	Article
author	Patwari, Muhammed Anayet Ullah Amin, A. K. M. Nurul Faris, Waleed Fekry
author_facet	Patwari, Muhammed Anayet Ullah Amin, A. K. M. Nurul Faris, Waleed Fekry
author_sort	Patwari, Muhammed Anayet Ullah
title	Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C)
title_short	Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C)
title_full	Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C)
title_fullStr	Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C)
title_full_unstemmed	Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C)
title_sort	identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (s45c)
publisher	Science Publications
publishDate	2010
url	http://irep.iium.edu.my/16686/ http://irep.iium.edu.my/16686/ http://irep.iium.edu.my/16686/ http://irep.iium.edu.my/16686/1/ajeas31193-200%5B1%5D.pdf
first_indexed	2023-09-18T20:25:26Z
last_indexed	2023-09-18T20:25:26Z
_version_	1777408385378942976

Identification of instabilities of the chip formation and it’s prediction model during end milling of medium carbon steel (S45C)

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