Advertisement

Cutting parameter optimization in shoulder milling of commercially pure molybdenum

  • Hüseyin Gökçe
  • İbrahim Çiftçi
  • Halil Demir
Technical Paper

Abstract

Due to its superior properties such as high melting point (2617 °C), high thermal conductivity and low thermal expansion at higher temperatures, molybdenum is a refractory metal and is used for making critical parts in defense, space, electronics and nuclear industries. High cost of molybdenum makes the selection of suitable cutting conditions imperative in machining operations in order to obtain the required surface quality and dimensional accuracy. In this study, suitable cutting tools and cutting parameters were aimed to be determined in terms of cutting forces (Fc) and average surface roughness (Ra) when shoulder milling commercially pure molybdenum. The milling tests were carried out at 0.05, 0.1, 0.15, 0.2 mm/tooth feed rates and 75, 100, 125, 150 m/min cutting speeds using four different cutting tools. The Taguchi’s experimental design (L16 orthogonal array) technique was implemented. Analysis of variance was used to determine the effects of cutting tools and cutting parameters on Ra and Fc. The results showed that the feed rate is the most influential parameter for Fc while the cutting speed is for Ra.

Keywords

Pure molybdenum ANOVA Surface roughness Cutting forces 

List of symbols

ap

Radial depth of cut (mm)

ae

Axial depth of cut (mm)

\(\bar{A}_{0}\)

Optimum S/N ratio for A (cutting tool) (dB)

\(\bar{B}_{0}\)

Optimum S/N ratio for B (feed rate) (dB)

\(\bar{C}_{0}\)

Optimum S/N ratio for C (cutting speed) (dB)

CI

Confidence interval

f

Feed rate (mm/tooth)

Fc

Main cutting force (N)

N

Total number of tests

\(\eta_{G}\)

S/N ratio calculated at optimum level (dB)

\(\bar{\eta }_{G}\)

S/N averages of control factors (dB)

neff

Confirmatory test number

Ra

Average surface roughness (µm)

S/N

Signal/noise ratio (dB)

Vc

Cutting speed (m/min)

Ve

Error variance

Notes

Acknowledgements

The authors would like to thank Karabuk University for provision of funding with the Project KBU-BAP-15/2-DR-002 and Cankiri Karatekin University for provision of laboratory facilities.

References

  1. 1.
    Groover MP (2010) Fundamentals of modern manufacturing: materials, processes and systems, 4th edn. Wiley, New YorkGoogle Scholar
  2. 2.
    Askeland RA, Fulay PP, Wright WJ (2010) The science and engineering of materials, 6th edn. CL Engineering, StamfordGoogle Scholar
  3. 3.
    Kalpakjian S, Schmid SR (2009) Manufacturing engineering and technology, 6th edn. Pearson Education, SingaporeGoogle Scholar
  4. 4.
    Savitskii EM, Burkhanov GS (1970) Physical metallurgy of refractory metals and alloy. Consultants Bureau, New YorkGoogle Scholar
  5. 5.
    Fan JLM, Cheng H, Tian J, Huang B (2009) Effect of alloying elements Ti, Zr on the property and microstructure of molybdenum. Int J Refract Metal Hard Mater 27:78–82CrossRefGoogle Scholar
  6. 6.
    Walser H, Shields JA (2007) Traditional and emerging applications of molybdenum metal and its alloys. International Molybdenum Association IMOA Newsletter, pp 1–16Google Scholar
  7. 7.
    Freeman RR (1956) Properties and applications of commercial molybdenum and molybdenum alloys. In: Technology of molybdenum and its alloys symposium, DetroitGoogle Scholar
  8. 8.
    Kuljanic E, Sortino M, Totis G (2010) Machinability of difficult machining materials. In: 14th International research/expert conference trends in the development of machinery and associated technology, vol 1, pp 1–14Google Scholar
  9. 9.
    Zlatin N, Field M, Gould J (1963) Machining of refractory materials. ASD Interim reportGoogle Scholar
  10. 10.
    Sortino M, Totis G, Prosperi F (2013) Dry turning of sintered molybdenum. J Mater Process Technol 213:1179–1190CrossRefGoogle Scholar
  11. 11.
    Shields JA (2013) Applications of molybdenum metal and its alloys. International Molybdenum Association IMOA Newsletter, pp 1–44Google Scholar
  12. 12.
    Trent EM, Wright PK (2000) Metal cutting, 4th edn. Butterworth Heinemann, OxfordGoogle Scholar
  13. 13.
    Wang W, Kweon SH, Yang SH (2005) A study on roughness of the micro-end-milled surface produced by miniatured machine tool. J Mater Process Technol 162–163:702–708CrossRefGoogle Scholar
  14. 14.
    ISO (4287:1997) Geometrical product specifications (GPS)—surface texture: profile method-terms, definitions and surface texture parameters. International Organization for Standardization, GenevaGoogle Scholar
  15. 15.
    Ghani JA, Choudhury IA, Hassan HH (2004) Application of Taguchi method in the optimization of end milling parameters. J Mater Process Technol 145:84–92CrossRefGoogle Scholar
  16. 16.
    Gunay M (2013) Optimization with Taguchi method of cutting parameters and tool nose radius in machining of AISI 316L steel. J Fac Eng Archit Gazi Univ 28:437–444Google Scholar
  17. 17.
    Gunay M, Yucel E (2013) Application of Taguchi method for determining optimum surface roughness in turning of high-alloy white cast iron. Measurement 46:913–919CrossRefGoogle Scholar
  18. 18.
    Boy M, Ciftci I, Gunay M, Ozhan F (2015) Application of the Taguchi method to optimize the cutting conditions in hard turning of a ring bore. Mater Technol 49:765–772Google Scholar
  19. 19.
    Selvaraj DP, Chandramohan P, Mohanraj M (2014) Optimization of surface roughness, cutting force and tool wear of nitrogen alloyed duplex stainless steel in a dry turning process using Taguchi method. Measurement 49:205–215CrossRefGoogle Scholar
  20. 20.
    Ciftci I (2005) The influence of cutting tool coating and cutting speed on cutting forces and surface roughness in machining of austenitic stainless steels. J Fac Eng Archit Gazi Univ 20:205–209Google Scholar
  21. 21.
    Ezugwu EO, Kim SK (1995) The performance of cermet cutting tools when machining an Ni–Cr–Mo (En 24) steel. Lubr Eng 51:139–145Google Scholar

Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2018

Authors and Affiliations

  1. 1.Vocational CollegeCankiri Karatekin UniversityMerkez, CankiriTurkey
  2. 2.Engineering FacultyCankiri Karatekin UniversityUluyazi, CankiriTurkey
  3. 3.Technology FacultyKarabuk UniversityBaliklar Kayasi, KarabukTurkey

Personalised recommendations