Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy
This comprehensive study investigates the micro-milling of a Mg13Sn alloy, a material of considerable interest in various high-precision applications, such as biomedical implants. The main objective of the study was to explore the optimizations of variable feed per tooth (fz), cutting speed (Vc), an...
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2023-08-01
|
| Series: | Micromachines |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2072-666X/14/8/1590 |
| _version_ | 1797583795647414272 |
|---|---|
| author | Ali Ercetin Kubilay Aslantaş Özgür Özgün Mustafa Perçin Manjunath Patel Gowdru Chandrashekarappa |
| author_facet | Ali Ercetin Kubilay Aslantaş Özgür Özgün Mustafa Perçin Manjunath Patel Gowdru Chandrashekarappa |
| author_sort | Ali Ercetin |
| collection | DOAJ |
| description | This comprehensive study investigates the micro-milling of a Mg13Sn alloy, a material of considerable interest in various high-precision applications, such as biomedical implants. The main objective of the study was to explore the optimizations of variable feed per tooth (fz), cutting speed (Vc), and depth of cut (ap) parameters on the key outcomes of the micro-milling process. A unique experimental setup was employed, employing a spindle capable of achieving up to 60,000 revolutions per minute. Additionally, the study leveraged linear slides backed by micro-step motors to facilitate precise axis movements, thereby maintaining a resolution accuracy of 0.1 μm. Cutting forces were accurately captured by a mini dynamometer and subsequently evaluated based on the peak to valley values for Fx (tangential force) and Fy (feed force). The study results revealed a clear and complex interplay between the varied cutting parameters and their subsequent impacts on the cutting forces and surface roughness. An increase in feed rate and depth of cut significantly increased the cutting forces. However, the cutting forces were found to decrease noticeably with the elevation of cutting speed. Intriguingly, the tangential force (Fx) was consistently higher than the feed force (Fy). Simultaneously, the study determined that the surface roughness, denoted by Sa values, increased in direct proportion to the feed rate. It was also found that the Sa surface roughness values decreased with the increase in cutting speed. This study recommends a parameter combination of fz = 5 µm/tooth feed rate, Vc = 62.8 m/min cutting speed, and ap = 400 µm depth of cut to maintain a Sa surface roughness value of less than 1 µm while ensuring an optimal material removal rate and machining time. The results derived from this study offer vital insights into the micro-milling of Mg13Sn alloys and contribute to the current body of knowledge on the topic. |
| first_indexed | 2024-03-10T23:44:04Z |
| format | Article |
| id | doaj.art-dd2a8d2d061d493bbd391b1aca90cf50 |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-03-10T23:44:04Z |
| publishDate | 2023-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-dd2a8d2d061d493bbd391b1aca90cf502023-11-19T02:14:05ZengMDPI AGMicromachines2072-666X2023-08-01148159010.3390/mi14081590Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn AlloyAli Ercetin0Kubilay Aslantaş1Özgür Özgün2Mustafa Perçin3Manjunath Patel Gowdru Chandrashekarappa4Department of Naval Architecture and Marine Engineering, Maritime Faculty, Bandırma Onyedi Eylul University, Bandırma 10200, TurkeyDepartment of Mechanical Engineering, Faculty of Technology, Afyon Kocatepe University, Afyonkarahisar 03200, TurkeyDepartment of Occupational Health and Safety, Faculty of Health Sciences, Bingöl University, Bingöl 12000, TurkeyDepartment of Machine and Metal Technologies, Vocational School of Technical Sciences, Bursa Uludag University, Bursa 16059, TurkeyDepartment of Mechanical Engineering, PES Institute of Technology and Management, Visvesvaraya Technological University, Belagavi 590018, IndiaThis comprehensive study investigates the micro-milling of a Mg13Sn alloy, a material of considerable interest in various high-precision applications, such as biomedical implants. The main objective of the study was to explore the optimizations of variable feed per tooth (fz), cutting speed (Vc), and depth of cut (ap) parameters on the key outcomes of the micro-milling process. A unique experimental setup was employed, employing a spindle capable of achieving up to 60,000 revolutions per minute. Additionally, the study leveraged linear slides backed by micro-step motors to facilitate precise axis movements, thereby maintaining a resolution accuracy of 0.1 μm. Cutting forces were accurately captured by a mini dynamometer and subsequently evaluated based on the peak to valley values for Fx (tangential force) and Fy (feed force). The study results revealed a clear and complex interplay between the varied cutting parameters and their subsequent impacts on the cutting forces and surface roughness. An increase in feed rate and depth of cut significantly increased the cutting forces. However, the cutting forces were found to decrease noticeably with the elevation of cutting speed. Intriguingly, the tangential force (Fx) was consistently higher than the feed force (Fy). Simultaneously, the study determined that the surface roughness, denoted by Sa values, increased in direct proportion to the feed rate. It was also found that the Sa surface roughness values decreased with the increase in cutting speed. This study recommends a parameter combination of fz = 5 µm/tooth feed rate, Vc = 62.8 m/min cutting speed, and ap = 400 µm depth of cut to maintain a Sa surface roughness value of less than 1 µm while ensuring an optimal material removal rate and machining time. The results derived from this study offer vital insights into the micro-milling of Mg13Sn alloys and contribute to the current body of knowledge on the topic.https://www.mdpi.com/2072-666X/14/8/1590micro-millingcutting forcesfeed ratesurface roughnessploughingmaterial removal rate (MRR) |
| spellingShingle | Ali Ercetin Kubilay Aslantaş Özgür Özgün Mustafa Perçin Manjunath Patel Gowdru Chandrashekarappa Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy Micromachines micro-milling cutting forces feed rate surface roughness ploughing material removal rate (MRR) |
| title | Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy |
| title_full | Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy |
| title_fullStr | Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy |
| title_full_unstemmed | Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy |
| title_short | Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy |
| title_sort | optimization of machining parameters to minimize cutting forces and surface roughness in micro milling of mg13sn alloy |
| topic | micro-milling cutting forces feed rate surface roughness ploughing material removal rate (MRR) |
| url | https://www.mdpi.com/2072-666X/14/8/1590 |
| work_keys_str_mv | AT aliercetin optimizationofmachiningparameterstominimizecuttingforcesandsurfaceroughnessinmicromillingofmg13snalloy AT kubilayaslantas optimizationofmachiningparameterstominimizecuttingforcesandsurfaceroughnessinmicromillingofmg13snalloy AT ozgurozgun optimizationofmachiningparameterstominimizecuttingforcesandsurfaceroughnessinmicromillingofmg13snalloy AT mustafapercin optimizationofmachiningparameterstominimizecuttingforcesandsurfaceroughnessinmicromillingofmg13snalloy AT manjunathpatelgowdruchandrashekarappa optimizationofmachiningparameterstominimizecuttingforcesandsurfaceroughnessinmicromillingofmg13snalloy |