Reason-A Technical Journal (Formerly Reason-A Technical Magazine)

Sanjib Kundu ¹, Santanu Das ¹, Partha Pratim Saha ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani, West Bengal 741235, IN

Abstract

Presence of burr after a manufacturing process is a potential problem. Prediction of burr size in machining plays an important role in process planning. The present work deals with the study and development of a burr height prediction model during machining aluminium alloy, using Response Surface Methodology (RSM). Drilling parameter such as cutting velocity, feed rate and drill diameter are considered in conducting experiments in a radial drilling machine to find out height of burr formed in aluminium alloy flats. By performing ANOVA, it is found that drill diameter is the most significant factor to influence formation of burr height. Combination of process parameters giving small burr height is found out within the experimental constraints. Three-dimensional surface and contour plots show the variation in burr height with different process parameters. A comparison of modeled and experimental results corresponding to a low burr height shows an error of less than 3%.

Keywords

Drilling, Burr Height, RSM, ANOVA, Size Effect.

Full Text

   

Partha Pratim Saha ¹, Santanu Das ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani, Nadia-741 235, West Bengal, IN

Abstract

Production of high precision components needs constant attention to both the generation of machined surfaces without a burr and undertaking deburring operation. A machining process usually produces burr. In shaping, burr formation occurs when the cutting tool exits the workpiece. Absence of necessary back up support around an edge is the possible reason behind it. Several research works have been done on burr formation mechanism, its minimization, and deburring. A number of experiments is performed in this work on medium carbon steel (45C8) flats in dry condition to note the effects of burr formation on the workpiece with beveled exit edge. The experimental result shows that at 15o edge bevel, negligible burr formation is obtained. Analysis of variance is conducted on the experimental results to find out the relative influence of each process parameter on burr height observed. The regression analysis is also done with the experimental data and the regression equation gives fairly good estimate of experimental results.

Keywords

Machining, Shaping, Edge Beveling, Exit Edge, Burr.

Full Text

   

Partha Pratim Saha ¹, Santanu Das ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani 741 235, West Bengal, IN

Abstract

Foot formation in the workpiece during shaping operation is not favourable with early tool fracture, when a cutter exits the workpiece edge. Foot formation occurs due to gradual rotation of the positive shear plane to the negative shear plane about a pivot point. A number of tests in shaping operation is done in the present work on nickel chrome steel (En25) flats. Experiments are carried out in dry environment under different cutting velocities, rake angles and exit edge bevel angles to note the effect of foot formation. Experimental results are analyzed through ANOVA to find out the significance of the effect of cutting parameters and exit edge bevel angle to minimize the foot formation. It is observed foot formation that an exit edge bevel angle has the most significant effect. An exit edge bevel angle of 150 is recommended in orthogonal shaping operation when no foot formation is found.

Keywords

Shaping, Edge Beveling, Foot formation, Shear Plane, ANOVA.

Full Text

   

Partha Pratim Saha ¹, Dipankar Das ¹, Santanu Das ¹

Affiliations
1 Dept. of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741 235, IN

Abstract

Presence of burr at the edge of finished workpiece often leads to difficulty in assembly operation and injury to operator necessitating incorporation of additional processes of deburring. Exit burr formation by milling usually occurs when cutter moves out of the work piece. One method for minimizing this problem is to prevent the tool from exiting the workpiece while removing material. Burr formation can also be reduced considerably by edge beveling of the workpiece. In the present work, the influence of beveling the exit edge of the workpiece on the burr formation in milling has been experimentally investigated to find out the optimum condition to control the formation of burr.

Full Text

   

Partha Pratim Saha ¹

Affiliations
1 Kalyani Government Engineering College, Jig & Tool Design Office, Eastern Railway, Kanchrapara Workshop, IN

Abstract

The competitive pressures are throwing new challenges to the business world. In past, quality acted as a distinguishing characteristic between a company and its competitors. In today's world, however, quality has become mandatory. It is an assumed characteristic. The distinguishing features then become verifiable quality, continuous improvement, innovation, superior customer service, etc.

Full Text