Depth of Cut

This paper presents a study on the influence of the cutting parameters (depth of cut, feed rate, and cutting speed) of turning with a carbide insert on the plastic deformation induced in annealed AISI-1020 steel. The results showed an increase in the deformation with each cutting parameter, due to the higher forces associated with the machining process and the cutting area. This causes an increase in the energy required for material cutting and,consequently, more cold work on the machined surface. The ANOVA analysis of the results showed that the feed rate had the most significant role in the resulting deformation (86.03%), and the cutting speed contributed less (6.81%). In addition, a mathematical expression for the prediction of deformation based on the evaluated parameters is proposed. RESUMEN: En este trabajo se presenta el estudio de la influencia de los parámetros de corte (profundidad de corte, velocidad de avance y velocidad de corte) del torneado con inserto de carburo sobre la deformación plástica inducida en el acero AISI-1020 recocido. Los resultados mostraron un aumento en la deformación con cada parámetro de corte debido al incremento tanto de las fuerzas asociadas al proceso de mecanizado como del área de corte, lo cual genera un aumento en la energía requerida para el corte del material, y, en consecuencia, mayor trabajo en frio sobre la superficie maquinada. El análisis ANOVA de los resultados mostró que la velocidad de avance tiene mayor influencia sobre la deformación resultante (86.03%) y la velocidad de corte tuvo una contribución menor (6,81%). Además, se propone una expresión matemática para la predicción de la deformación a partir de los parámetros evaluados.

The machining of FG300 gray cast iron flanges is critical in various industrial applications, requiring optimized parameters to enhance surface quality, reduce tool wear, and improve efficiency. The goal of this research is to maximise cutting depth, feed rate, and speed using a Minimum Quantity Lubrication (MQL) system, which is a sustainable substitute for traditional cooling techniques. MQL minimizes lubricant consumption while ensuring effective cooling and lubrication, contributing to sustainable manufacturing. Turning experiments were conducted using carbide cutting tools under controlled MQL conditions. Tool wear and surface roughness (Ra) were examined as important performance metrics.  The statistical significance of the machining parameters and their impact on the responses were evaluated using the Analysis of Variance (ANOVA) approach.  The findings show that cutting speed has the greatest impact, followed by feed rate and cut depth. The optimized parameters led to improved surface finish, reduced tool wear, and enhanced machining efficiency. This study provides a systematic approach for optimizing machining parameters under MQL conditions, offering valuable insights for industries seeking to enhance productivity while reducing costs and environmental impact. The findings demonstrate that ANOVA-based optimization under MQL can significantly improve the machining of FG300 flanges, making it a promising approach for sustainable and high-precision manufacturing.

In the present study genetic algorithm was used to optimize the turning process parameters to obtain maximum material removal rate. The prediction of optimal machining condition for material removal rate plays an important role in process planning. Thus the objective of present study was to develop an empirical model to predict material removal rate in terms of spindle speed, feed rate and depth of cut using multiple regressions modeling method. Experiments were carried out on NC controlled machine tool by taking AlMg1SiCu as workpiece material and carbide inserted cutting tool. Finally, genetic algorithm has been employed to find out the optimal setting of process parameters that optimize material removal rate. The best response value for material removal rate obtained from single objective optimization by genetic algorithm was 6021.411 mm/min. Comparisons of experimental and predicted results at optimum conditions showed an error of 3.35 %.This provides flexibility to the manufact...

By increasing the daily needs of human energy, human manipulation of natural energy sources is expanded and encouraged the human society to developing science, knowledge and technology. Mechanical specific energy required energy for drilling the unit of formation volume. This parameter can be used for functional analysis of drilling, drilling bit optimization and investigating of instability has been made during drilling operations. This parameter can be used for decreasing of drilling costs by increasing drilling speed, optimized the useful life of the drilling bit and determine the right time to replace the drilling bit, and in some cases reduced to a minimum amount. In South Pars field in Iran, many wells have been drilled; however detailed statistics processes hadn't done for optimizing drilling parameters and their impact on mechanical specific energy. By results of these studies, we can analyze performance and drilling parameters such as weight on drilling bit, rotational speed, penetration rate, etc. In the most investigated cases, mechanical specific energy at the final period time of drilling on each wells has been increased gradually due to the speed movement reduction. Although by investigating middle formations in section of 12.25 inch, all existing wells on a platform in one of the phases of Iran's South Pars field are being studied, which contains formations such as Hith, Surmeh, Neyriz, Dashtak and Kangan. Studies were done in two parts. In the first part, the range of optimized drilling parameters that is increasing drilling speed and reducing the required amount of energy for drilling formation. This process by investigating mechanical specific energy and its relationship with uniaxial compressive strength in five studied formation have been presented. In the second part, correlations to predict the mechanical specific energy in this area by statistical methods by SPSS software, presented and reviewed. Then, by the most appropriate rela-

By increasing the daily needs of human energy, human manipulation of natural
energy sources is expanded and encouraged the human society to developing
science, knowledge and technology. Mechanical specific energy required
energy for drilling the unit of formation volume. This parameter can
be used for functional analysis of drilling, drilling bit optimization and investigating
of instability has been made during drilling operations. This parameter
can be used for decreasing of drilling costs by increasing drilling speed,
optimized the useful life of the drilling bit and determine the right time to replace
the drilling bit, and in some cases reduced to a minimum amount. In
South Pars field in Iran, many wells have been drilled; however detailed statistics
processes hadn’t done for optimizing drilling parameters and their impact
on mechanical specific energy. By results of these studies, we can analyze performance
and drilling parameters such as weight on drilling bit, rotational
speed, penetration rate, etc. In the most investigated cases, mechanical specific
energy at the final period time of drilling on each wells has been increased
gradually due to the speed movement reduction. Although by investigating
middle formations in section of 12.25 inch, all existing wells on a platform in
one of the phases of Iran’s South Pars field are being studied, which contains
formations such as Hith, Surmeh, Neyriz, Dashtak and Kangan. Studies were
done in two parts. In the first part, the range of optimized drilling parameters
that is increasing drilling speed and reducing the required amount of energy
for drilling formation. This process by investigating mechanical specific
energy and its relationship with uniaxial compressive strength in five studied
formation have been presented. In the second part, correlations to predict
the mechanical specific energy in this area by statistical methods by
SPSS software, presented and reviewed. Then, by the most appropriate relationship, the most influential drilling parameters on mechanical specific
energy have been set. However, for drilling the next wells in this area drilling
parameters with the most priority influences on mechanical specific energy,
proposed in the optimum range, will be recommended.

In ultra-precision machining, the heating effect on a workpiece induced by cutting process itself plays an important role in the machining process as it affects tool life, machining accuracy, and the surface quality of the workpiece. This paper discusses the cutting-induced heating effect in ultra-precision raster milling based on the study of the time-temperature-dependent precipitation of 6061 aluminum alloy. Experiments are designed to estimate the temperature variation of the workpiece in ultra-precision machining by comparing the change in the size of precipitates in isothermal heat treatment with those in raster milling process under different depth of cut. Microscopical examination under a scanning electron microscope (SEM) revealed that the temperature on the raster-milled surface is much higher than 500°C. In the last part of this paper, the heat generation of the workpiece in the process of ultraprecision raster milling is simulated by finite element method, the result of which is found to be consistent with that from SEM.

Cement concrete is an adaptable building development material in structural designing and it is likewise one of the world's most broadly utilized development material around the globe in all development ventures and in numerous development applications. Essentially cement concrete is a composite blend of concrete, very much evaluated fine totals and coarse totals, water and admixtures. Development exercises and activities are expanding the world over which has come about into the extreme extraction and use of normally accessible materials like common waterway sand, stones and shakes, lime, earth, water and so forth. As of now the issues confronted by the utilization of cement concrete incorporates popularity of concrete solid, expense of bond and solid making materials, contamination, over the top extraction and use of common stream sand and stones, water and so forth. Since the sand is as a rule widely extricated from the waterway bed stores, it is exhausting at a speedier rate...

The acoustic emission (AE) characterisation in face milling of the biomaterial magnesium-caused 1.0 alloy is presented in this research. The material removal mechanism in machining has a significant impact on the surface quality. The mechanics of surface and sub-surface production during machining can be better understood by looking at the AE parameters, such as energy and number of counts. As a result, AE signals generated during machining were recorded and their impacts on the feed rate, depth of cut, and cutting speed were analysed.

Design and analysis of optimisation protocols used for performance enhancement of machining based components manufacturing is currently an active area of machining science. This experimental investigation research deals with determining and optimising the effects of three input parameter metrics on the performance realisation of good surface quality output and energy consumption during the dry machining process of EN 24 steel material by turning on the CNC lathe. The input parameter metrics considered were cutting speed, depth of cut and feed rate. The study, employed Taguchi full factorial design approach in planning the experimental process and estimate the effects of the input metrics on the response; three phase digital energy meter to capture electrical power consumption data online; offline recorded surface roughness data and used Minitab 18 statistical software analysis of variance to assess the influence of cutting parameters on the response parameters, and the Signal to noise ratio main effects plot as the optimisation tool for the various response parameters. The paper aimed to determine the appropriate cutting parameter settings required on the lathe machine in order to produce EN 24 components of better surface quality at minimum energy expenditure. The experimental data analysis results established the optimum operating conditions at varied cutting parameter settings with respect to the different response parameters and the results were presented for the surface roughness, material removal rate and specific cutting energy use.

This study investigates the influence of machining time on surface roughness characteristics during the turning process of oil-hardening non-shrinking (OHNS) die steel. Two sets of experiments were conducted utilizing different materials and inserts to comprehensively analyze the machining process's effects on surface quality. In the first set of experiments, E0300 alloy steel material was utilized, and turning operations were performed using CNMG120404EM6630 CNMG120408EM6630, CCMT09T308PM422, DNMX150608WM1525 insert under dry and wet cutting conditions. Surface roughness measurements were taken at various machining times to assess the evolution of surface quality over time. In the subsequent experiment, En31 alloy steel material was employed, and turning operations were conducted same inserts. Similar surface roughness measurements were obtained to compare the influence of machining time on surface quality between different materials and insert types. Comparisons between different materials and insert types reveal variations in surface roughness trends, highlighting the importance of material properties and cutting tool selection in achieving desired surface quality during turning operations

The objective of this study is to illustrate procedure adopted in Taguchi method for sheet metal processing on a drilling machine. The orthogonal array, signal-to-noise ratio and the analysis of variance are employed to study the performance characteristics in drilling operation. In this analysis, three factors namely speed; feed and depth of cut are considered. This paper deals with optimization of Drilling machine process parameter to provide good surface finish as well as high surface removal rate used as quality attributes and are considered to be directly related to productivity. Taguchi method is a statistical approach to optimize the process parameters and improve the quality of components that are to be

Abrasive water jet machining is a process that removes material using sand and water. This versatile process uses a high-pressure water jet loaded with abrasive particles of mineral origin. It allows the machining of all materials and is particularly suitable for machining or stripping applications on hard metal sheets. Due to a local action, the abrasive water jet limits heating and deformation. During machining, the removal of material occurs abrasion and erosion [1]. The identification of the respective importance of this abrasion and this erosion conditions the precision of the modeling of the machined depth. In this study, these mechanisms are presented and characterized for machining on 6mm thickness TiAl6V titanium alloys sheets with or without inclination of the jet. It is possible to model an elementary passage and it allows predicting the pocket bottom profile obtained after a succession of passages. During machining, two mechanisms appear. Abrasion occurs when machining a...

In today's manufacturing market, quality and productivity play significant role. This study is aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality and as well as productivity. This study investigates the effects of various parameters such as depth of cut, speed and feed on the material removal rate and surface roughness in a HMT (Hindustan Machine Tools) LB25 Lathe Machine. A plan of experiments based on Taguchi's technique has been used to acquire the data. An orthogonal array, the signal to noise (S/N) ratio and the analysis of variance (ANOVA) were employed to investigate the cutting characteristics of 1045 carbon steel using tungsten coated carbide cutting tool. The effectiveness of the predicted values with the experimental values in the analysis was carried out by confirmation tests. The analysis of results shows that the combination of process parameters for minimum surface roughness is obtained at 330 rpm spindle speed, 0.2 mm/rev feed and 0.6mm depth of cut for minimum surface roughness. It is observed that feed rate plays an important role in minimizing surface roughness. For maximum material removal rate, the optimum values are spindle speed of 630 rpm, feed rate of 0.4 mm/ rev and depth of cut of 1.0 mm. Finally, the relationship between cutting parameters and responses were developed by using the Minitab 18.1 software and regression equations were developed.

In the present investigation, the influence of machining parameters including cutting speed, feed rate and depth of cut on surface roughness (Ra) in a dry turning environment for hard AISI M2 are investigated using the Taguchi method and analysis of variance (ANOVA). A three level, three parameter design of experiment, the L27 orthogonal array using Minitab 17 software, the single to noise (S/N) ratio are employed to study the performance characteristic in the turning of hard AISI M2 by taking nose radius of the PCBN insert (Kennametal) of 0.8mm.The analysis of variance (ANOVA) is applied to investigate the percentage contribution of each machining parameters.The results are verified by taking confirmation experiments.The present study indicates that cutting speed is the most influencing factor for surface roughness.

The work presented in this paper examines the effects of cutting parameters (cutting speed, feed rate and depth of cut) onto the surface roughness through the mathematical model developed by using the data gathered from a series of turning experiments performed. An additional investigation was carried out in order to evaluate the influence of two well-known coating layers onto the surface roughness. For this purpose, the experiments were repeated for two CNMG 120408 (with an ISO designation) carbide inserts having completely the same geometry and substrate but different coating layers, in a manner that identical cutting conditions would be ensured. The workpiece material machined was cold-work tool steel AISI P20. Of the two types of inserts employed; Insert 1 possesses a coating consisting of a TiCN underlayer, an intermediate layer of Al 2 O 3 and a TiN outlayer, all deposited by CVD; whilst Insert 2 is PVD coated with a thin TiAlN layer (3 ± 1 m). The total average error of the model was determined to be 4.2% and 5.2% for Insert 1 and Insert 2, respectively; which proves the reliability of the equations established.

Surface finish and material removal rate are two important factors in the manufacturing which affect acceptability of the product which in turn reflects on the profitability of the organization. The worth of the production setup to produce the components with high material removal rate (MRR) without sacrificing the surface requirements can play vital role in sustainability and profitability of the organization. In this paper, the effect of process parameters on metal removal rate and surface roughness has been investigated in milling of AL material with Carbide end mill cutter. Cutting speed, feed and depth of cut have been taken as input factors in three level response surface methodologies used for experimentation. Mathematical models have been developed using response surface methodology to predict surface finish, and metal removal rate in term of machining parameters. Depth of cut and feed rate are found to be a dominant parameter for surface roughness; whereas feed rate mainly ...

Drilling into harsh environment with heterogeneous formations including chert or conglomerate is usually a boundary that can't be crossed with standard PDC bit technology. This paper will show how an innovative PDC cutter shape combined with a novel 3D approach of cutting structure design have withstood this challenge and successfully replaced 16-in. traditional roller cone application in United Arab Emirates by the latest PDC technology delivering an average 35% improvement on Rate Of Penetration (ROP) while continuously drilling to Total Depth (TD) on each section. When drilling chert or conglomerate type of formation with a PDC drill bit, uneven load per cutters is detrimental to their integrity and results in short runs or brutal stop in the drilling operation triggering a trip for drill bit change. The new technology shown in this paper includes a unique hybrid combination of cutter shapes with a design arrangement of the cutting structure to allow for the pre-fracturing of...

Optimum Selection of cutting conditions importantly contribute to the increase of productivity and the reduction of cost, therefore utmost attention is paid to this problem in this contribution. In this paper, a neural network based approach to complex optimization of cutting parameters is proposed. To reach higher precision of the predicted results a neural optimization algorithm is developed and presented to ensure simple, fast and efficient optimization of all important turning parameters. The approach is suitable for fast determination of optimum cutting parameters during machining, where there is not enough time for deep analysis. Surface roughness, an indicator of surface quality is one of the most specified customer requirements in a machining process. To predict the surface roughness, an Artificial Neural Network (ANN) model was designed through back propagation network using MATLAB 7.1 software for the data obtained.

Surface roughness and tool wear is one of the most specified customer requirements in a machining process. To predict the surface roughness and tool wear, Genetic Algorithm& Image processing model was designed through MATLAB 7.1 software for the data obtained.

The objective of this study is to illustrate procedure adopted in Taguchi method for sheet metal processing on a drilling machine. The orthogonal array, signal-to-noise ratio and the analysis of variance are employed to study the performance characteristics in drilling operation. In this analysis, three factors namely speed; feed and depth of cut are considered. This paper deals with optimization of Drilling machine process parameter to provide good surface finish as well as high surface removal rate used as quality attributes and are considered to be directly related to productivity. Taguchi method is a statistical approach to optimize the process parameters and improve the quality of components that are to be

The surface finish of the machining part is the mostly important characteristics of products quality and its indispensable customers’ requirement. Taguchi robust parameters designs for optimizing for surface finish in turning of 7025 AL-Alloy using carbide cutting tool has been utilized in this paper. Three machining variables namely; the machining speeds (1600, 1900, and 2200) rpm, depth of cut (0.25, 0.50, 0.75) mm and the feed rates (0.12, 0.18, 0.24) mm/min utilized in the experiments. The other variables were considered as constants. The mean surface finish was utilized as a measuring of surface quality. The results clarified that increasing the speeds reduce the surface roughness, while it rises with increasing the depths and feeds. Using the analysis of variance, it found that the most effective variable is cutting speed with (53.85%) and the depths has the smallest influence with (20.09%). The data set from the experiments was appointed for implementing the optimum procedure...

Quality of product and process are mainly depends upon their process parameters and their levels selected for design and manufacturing. So, it is important to decide optimal levels of process parameters to get desired output variables. The study focuses on finding out optimal levels of process parameters in Resistance Spot Welding (RSW) and its effect on tensile strength and nugget diameter. The Response Surface Methodology (RSM) is employed for multi objective optimization of responses for maximizing tensile strength and minimizing nugget diameter. Response optimizer with desirability function is found for optimum results of response surface methodology. Analysis of variance (ANOVA) is carried out for analyzing contribution of each process parameter on the performance of RSW.

The goal is to study the influence of abrasive water jet (AWJ) machining parameters (jet pressure, traverse speed and scan step) on the cutting depth of 3D woven Carbon Fibres Reinforced Polymer (CFRP) composite. The original material linked to this non-conventional milling process has not been treated yet. The depths of cut were measured and characterized as a function of the machining parameters. Finally, two prediction models for the cutting depth are proposed and validated experimentally. An increase in cutting depth with the pressure and a decrease as the traverse speed and/or the scan step increase were observed. The first prediction model, based on the pocket depth measurements, has a mean error of 5%. However, the error increases (up to 23%) when the pocket becomes shallow (lesser than 1 mm). The second prediction model, based on the algebraic sum of elementary passes modelled with Gaussian bells, shows at first a mean error of 12%. A correction was performed depending on the erosion regime piloted by the depth of the elementary trench constitutive of the pocket. This enhancement, performed thanks to the primary jet diameters measurements with high speed camera, has improved the second model with a mean error of 5% (error < 16%).

This paper reports on the effect of coolant temperature on machining of high carbon steels. The development of a cooling system to reduce the temperature of water soluble coolant to 7.9 o C from ambient temperature was employed in this work to improve the machining performance. The experiments were performed using cooled and ambient temperatures by employing Taguchi L 18 orthogonal array to design the experimental runs. The cutting speed, feed rate and depth of cut were the machining parameters used; while the tool-work piece interface temperature was monitored using a digital thermometer with k-type thermocouple wire. The selected control factors are material removal rate and surface roughness. The experimental results were analyzed using Minitab 16. The main effects and percentage contributions of various parameters affecting surface roughness and material removal rate were discussed, and the optimal cutting conditions were determined. It was observed that surface finish improved ...

I would like to express my immeasurable thanks to Professor Bernt Aadøy (Faculty Supervisor), Jackob Steina and Knut Skinnaland (Impetro International), Mike Herbert (Conocophillips contact among others) and Tonje Helgaland (Sperry Drilling-Halliburton) for their encouragement, contributions and guidance. My appreciation goes to God Almighty for his bestowed courage and strength for the completion of this project work. Thanks to my classmates and friends for their co-operations and understanding.

At their advent, PDC bits were aimed at soft formation, fast drilling applications. However, as PDCs have come to dominate market share over roller cones, PDC bit development has shifted focus toward other goals such as durability and longevity which is often in conflict with high ROP. Returning focus to aggressive, high ROP drilling applications has required development of materials, design and manufacturing processes in alignment with that goal set. A cross-functional team was assembled to understand and focus on the high ROP concerns of the end customer and was tasked to develop a PDC bit platform aligned with these goals. This paper discusses general and application specific challenges posed by high ROP drilling applications and how they have been addressed by the aligned development of a new system of materials, design, and manufacturing processes used in PDC drill bits. Formation to bit interaction simulations and computational fluid dynamic modeling analysis are presented in support of the development hypotheses. Field results from case studies and broad field data analysis summarizing the results of extensive testing are presented as well. Driving ROP beyond the ceilings observed in many extreme ROP applications requires that energy be efficiently transferred not just to the bit, but focused on the cutters. To achieve this, an essential change to the base material of the bit body was made, exposing drastically new avenuesand hurdlesfor design and manufacturing. However, the simulation and field results presented confirm that the new system is able to consistently achieve the goal set in high ROP applications.

The overarching aim of this work is to optimize the various process parameters involved in turning of EN 24 Steel alloy using Tungsten Carbide inserts to enhance the tool life and surface finish. Appropriate or random selection of cutting parameters have serious effect over the final output responses such as Surface Roughness , Tool life and other related properties of both the work piece and tool. Controlling the effective parameters is the need of the hour in any product manufacturing system. In the present work three different turning process parameters such as Cutting Speed, Feed rate and Depth of cut are considered for optimization study by varying them with three levels. The experimental design matrix for conducting experiments were prepared using Taguchi's Orthogonal Array and calculation of Signal to Noise ratio is done for identifying the best combination of parameters. Through ANOVA it is observed that Cutting speed is the most influencing parameter with a maximum contribution of 80.23% comparing to the other input parameters over surface roughness. The S/N ratio method (Smaller is Better) have shown that the parameter level combination A3B1C1 (2000m/min, 0.05 mm/rev, 0.2 mm) can provide good surface finish of the material with enhanced tool life.

This experiment reviews the optimization of cutting parameters for surface roughness & material removal rate in the turning process to obtain the optimal setting for the process parameters and analysis of variance is used to analysis the influence of cutting parameters while machining. Orthogonal array is also been used and prepared to obtain the optimal levels and to analyse the effect of each turning parameters. The S/N ratio is been calculated to structure the ANOVA table and  study the performance characteristics in turning process. ANOVA analysis gives the contribution percentage of every process parameter. The number of experiments are to be obtained using full factorial design for optimal result.

The main purpose of cutting fluid in a machining is to cool the work piece, reduce friction, and wash away the chips. Introducing cutting fluid in a metal-cutting process can reduce the rate of tool wear and improve surface quality also. The large usage of cutting fluid causes hike in machining cost as well as environmental threats. In the past, there have been some attempts to minimize the amount of cutting fluid in turning. To accomplish that purpose, a minimal-cutting-fluid system was developed. In the present investigation a specially formulated cutting fluid with rich water as 80% applied as a high velocity, thin pulsed jet at the immediate cutting zones at an extremely low rate of 8 ml/min by using a minimal fluid application system during turning of Oil hardened non shrinkable steel. In this investigation the work piece selected was OHNS steel. The performance of hard turning of OHNS steel with minimal cutting fluid is studied and then compared with conventional wet and dry turning. The minimal fluid application system can reduce environmental pollution, improves machining performances, and consequently reduces total production cost because of minimum consumption of cutting fluid.

As per the present manufacturing scenario, focus of all manufacturing organizations, is to produce good quality product with a minimum cost. CNC turning process is the most common machining process that is used in now days. Present work has been done, to optimize the machining parameters, for material AL 6061 like, depth of cut, feed rate and cutting speed. MINITAB software is used for formulating the matrix and, for the analysis of regression and response surface methodology.

The estimation of Polycrystalline Diamond Compact (PDC) cutters wear has been an area of concern for the drilling industry for years now. The cutter's wear has been measured practically by pulling the bit out for evaluation at the surface. It is important to find the right time for tripping out as this helps to avoid the fishing job and reduces the operational cost significantly. The prediction of the drilling performance is based on the interaction of cutter and rock. Several authors focused on the cutter-rock interface but only a few researchers tried to model the wear of the PDC bit cutters. The aim of this research is to understand the relationships between the rate of penetration (ROP) and the drilling variables per each foot, and then determine the overall bit efficiency for the whole drilling operation. A new mathematical model is derived to predict the PDC bit performance by considering the factors that were already not taken into account. These factors include rock strength, bit design, and bit hydraulic. The model investigates the effect of these parameters to estimate the abrasive cutters wear on the inner and the outer bit cones by deriving modified equations to calculate the mechanical specific energy (MSE), torque, and depth of cut (DOC) as a function of effective blades (EB). The model is used to forecast the bit cutters wear conditions in four wells in the oil fields located in Libya, which were drilled with three different PDC's sizes. The model enables the results to be compared to the actual bit cutters wear measured for inner and outer cones. The results are found that are well in agreement with the actual field data obtained in bit records.

The overarching aim of this work is to optimize the various process parameters involved in turning of EN 24 Steel alloy using Tungsten Carbide inserts to enhance the tool life and surface finish. Appropriate or random selection of cutting parameters have serious effect over the final output responses such as Surface Roughness , Tool life and other related properties of both the work piece and tool. Controlling the effective parameters is the need of the hour in any product manufacturing system. In the present work three different turning process parameters such as Cutting Speed, Feed rate and Depth of cut are considered for optimization study by varying them with three levels. The experimental design matrix for conducting experiments were prepared using Taguchi's Orthogonal Array and calculation of Signal to Noise ratio is done for identifying the best combination of parameters. Through ANOVA it is observed that Cutting speed is the most influencing parameter with a maximum contribution of 80.23% comparing to the other input parameters over surface roughness. The S/N ratio method (Smaller is Better) have shown that the parameter level combination A3B1C1 (2000m/min, 0.05 mm/rev, 0.2 mm) can provide good surface finish of the material with enhanced tool life.

Rock cutting is a challenging problem from a modeling perspective. The challenges come from the complexity of the physics from the tool-rock interaction to the fracture process and propagation of the quasibrittle rocks. This study was aimed at developing a finite element procedure that was capable of providing reasonable estimates of cutting forces and, at the same time, capturing the essential characteristics of the fragmentation process. Published laboratory rock scratch tests were used as modeling targets since these tests encompass all essential characteristics of rock. Both shallow cuts and deep cuts from a rectangular cutter were analyzed first, and followed by modeling of shallow cuts from a disc cutter. It was concluded that rock cutting could be reasonably modeled by using a plasticity-damage model, an element erosion scheme that remove an element when its energy release equals fracture energy, together with a proper selection of modeling parameters.

This experiment reviews the optimization of cutting parameters for surface roughness & material removal rate in the turning process to obtain the optimal setting for the process parameters and analysis of variance is used to analysis the influence of cutting parameters while machining. Orthogonal array is also been used and prepared to obtain the optimal levels and to analyse the effect of each turning parameters. The S/N ratio is been calculated to structure the ANOVA table and  study the performance characteristics in turning process. ANOVA analysis gives the contribution percentage of every process parameter. The number of experiments are to be obtained using full factorial design for optimal result.

Penelitian ini bertujuan untuk mengetahui pengaruh parameter depth of cut terhadap hasil kekasaran permukaan dan laju korosi pada spesimen cancellous screw. Bagaimana cara menghasilkan kekasaran permukaan serendah mungkin dengan memvariasikan nilai depth of cut pada spesimen cancellous screw tanpa memberikan efek buruk terhadap spesimen cancellous screw yang menjadi fokus utama dalam penelitian ini. Karena nilai kekasaran permukaan yang rendah akan menekan nilai laju korosi pada spesimen cancellous screw. Sehingga akan aman jika diaplikasikan pada bahan implan tulang dalam tubuh manusia. Maka dari itu dalam penelitian ini dilakukannya proses turning pada round bar Stainless Steel 316L dengan variasi depth of cut yaitu: 0.2 mm; 0.3 mm; 0.4 mm; 0.5 mm dan 0.6 mm. Hasil proses turning dilakukan pengujian kekasaran permukaan dengan menggunakan alat Surface Roughness Tester SJ-301 Mitutoyo dan laju korosi dengan menggunakan alat Potentiostat / Galvanostat / Impedance Analyze (PalmSens 4), serta Scanning Electron Microscope (SEM) dan foto makro sebagai data pendukung yang juga digunakan dalam penelitian ini. Hasil analisis dari penelitian ini menunjukan bahwa depth of cut berpengaruh terhadap kekasaran permukaan dan laju korosi, dimana semakin rendahnya nilai depth of cut maka kekasaran permukaan akan menurun serta laju korosinya pun juga akan menurun, dan didapatkannya hasil paling terbaik yang diperoleh dari nilai depth of cut 0.2 mm dengan kekasaran permukaan yaitu sebesar 0,422 µm dan laju korosi sebesar 0,0515 mm/year. Kata kunci :stainless steel, depth of cut, cancellous screw, kekasaran permukaan, laju korosi.

In the present research, two real-time rock strength determination models based on the drilling parameters were studied. Firstly, a discrete element software named Particle Flow Code in 2 Dimensions (PFC 2D) was used to analyze the applicability of rock drillability index and drilling specific energy, in which graded particle assemblies were created to simulate the rock behaviour. In the numerical models, Weibull distribution was used to randomize the bonds between particles and make the assembled rock model with different heterogeneity. The drilling process of a PDC (polycrystalline diamond compact) cutter was modelled in two steps: horizontal linear rock cutting and vertical pressing-in progress. From the horizontal linear rock cutting process, the peak cutting forces were obtained and vertical pressing-in process outputs the relationship between normal force and cutting depth. Subsequently, the methods for calculating rock drillability index and drilling specific energy were proposed in the discrete element model. Then, the relationship between the calculated indexes and rock strength was investigated (supported with the regression analysis). Moreover, the effect of rock heterogeneity, along with error comparison between the above two indexes, were discussed. The results showed that the rock drillability index is more accurate than drilling specific energy in rock strength assessment (The error is about 10% smaller). INDEX TERMS Rock drillability index, drilling specific energy, heterogeneity, discrete element method, cutting force.

An automated drilling system requires a real-time evaluation of the drilling bit during drilling to optimize operation and determine when to stop drilling and switch bits. Furthermore, in the dynamic modeling of drill strings, it is necessary to take into account the interactions between drilling bits and rock. To address this challenge, a hybrid approach that combines physics-based models with data analytics has been developed to handle downhole drilling measurements in real time. First, experimental findings were used to formulate mathematical models of cutter–rock interaction in accordance with their geometrical characteristics, rock properties, and drilling parameters. Specifically, these models represent the normal and contact forces of polycrystalline diamond compact cutters (PDCs). Experimental data are analyzed utilizing deep learning, nonlinear regression, and genetic algorithms to fit nonlinear equations to data points. Following this, the recursive least square was implem...

Abstract: In this experiment we are primarily focusing on the Enhancement of Cutting tool life of CNC Lathe machine. In turning operation the properties of tools, work-pieces and different input parameters affect the output characteristics and efficiency of the machine. Improvement in process efficiency can be obtained by optimization of different input parameters which leads to required or desired output with acceptable variations in values.

Rock cutting is a challenging problem from a modeling perspective. The challenges come from the complexity of the physics from the tool-rock interaction to the fracture process and propagation of the quasibrittle rocks. This study was aimed at developing a finite element procedure that was capable of providing reasonable estimates of cutting forces and, at the same time, capturing the essential characteristics of the fragmentation process. Published laboratory rock scratch tests were used as modeling targets since these tests encompass all essential characteristics of rock. Both shallow cuts and deep cuts from a rectangular cutter were analyzed first, and followed by modeling of shallow cuts from a disc cutter. It was concluded that rock cutting could be reasonably modeled by using a plasticity-damage model, an element erosion scheme that remove an element when its energy release equals fracture energy, together with a proper selection of modeling parameters.

In this study, machinability test was conducted on Al-Nanoclay metal matrix composites using lathe tool dynamometer. Composites were prepared with aluminium as the matrix and nanoclay particles with 2, 4, 6 percentage by weight as reinforcement. The effect of clay particles and machining parameters such as cutting speed, feed rate and depth of cut on tangential force and chip formation was studied. From the results it is observed that the tangential force applied by the tool on MMC, facilitate chip breaking and the generation of chips significantly depends on feed but almost independent of speed. These results reveal the roles of the nanoclay reinforcement particles on the machinability of MMCs and provide a useful guide for a better control of their machining processes.

Nowadays, the demand for high product quality focuses extensive attention to the quality of machined surface. The (CNC) milling machine facilities provides a wide variety of parameters setup , making the machining process on the glass excellent in manufacturing complicated special products compared with other machining processes. However, the application of grinding process on the CNC milling machine could be an ideal solution to improve the product quality, but adopting the right machining parameters is required. Taguchi optimization method was used to estimate optimum machining parameters with standard orthogonal array L 16 (4 4) to replace the conventional trial and error method as it is time-consuming. Moreover, analyses on surface roughness and cutting force are applied which are partial determinant of the quality of surface and cutting process. These analyses are conducted using signal to noise (S/N) response analysis and the analysis of variance (Pareto ANOVA) to determine which process parameters are statistically significant. In glass milling operation, several machining parameters are considered to be significant in affecting surface roughness and cutting forces. These parameters include the lubrication pressure, spindle speed, feed rate, and depth of cut as control factors. While, the lubrication direction is considered as a noise factor in the experiments. Finally, verification tests are carried out to investigate the improvement of the optimization. The results showed an improvement of 49.02% and 26.28% in the surface roughness and cutting force performance, respectively.

The goal is to study the influence of abrasive water jet (AWJ) machining parameters (jet pressure, traverse speed and scan step) on the cutting depth of 3D woven Carbon Fibres Reinforced Polymer (CFRP) composite. The original material linked to this non-conventional milling process has not been treated yet. The depths of cut were measured and characterized as a function of the machining parameters. Finally, two prediction models for the cutting depth are proposed and validated experimentally. An increase in cutting depth with the pressure and a decrease as the traverse speed and/or the scan step increase were observed. The first prediction model, based on the pocket depth measurements, has a mean error of 5%. However, the error increases (up to 23%) when the pocket becomes shallow (lesser than 1 mm). The second prediction model, based on the algebraic sum of elementary passes modelled with Gaussian bells, shows at first a mean error of 12%. A correction was performed depending on the erosion regime piloted by the depth of the elementary trench constitutive of the pocket. This enhancement, performed thanks to the primary jet diameters measurements with high speed camera, has improved the second model with a mean error of 5% (error < 16%).

Grinding process is surface finishing process generally used to smoothen the surfaces by removing the limited quantity of material from the already machined surfaces. Cylindrical grinding or abrasive machining is the most popular machining process of removing metal from a work piece surface in the form of tiny chips by the action of irregularly shaped abrasive particles. In the present study, Taguchi method or Design of experiments has been used to optimize the effect of cylindrical grinding parameters such as wheel speed (rpm), work speed, feed (mm/min.), depth of cut and cutting fluid on the Material Removal Rate of EN15AM steel. Material removal rate measurements were carried out during the machining process on the work piece. EN15AM steel is generally known as free cutting steel and consists of higher machinability. It has several industrial applications in manufacturing of engine shafts, connecting rods, spindles, connecting components etc. The results indicated that grinding w...

Determination of tool wear and correspondingly tool life is extremely important in CNC turning operations. Enhancing the quality of the workpiece and reducing the cost to produce it is only possible by the optimization of process parameters, namely, cutting speed, feedrate, and depth of cut. Amount of tool wear can be minimized and the roughness of the surface can be enhanced by the optimization of process parameters. In this study, St 33 and St 52 steel samples were turned for 15 minutes on a CNC lathe using K20 sintered carbide inserts at predetermined process parameters, cutting speed, feedrate, and depth of cut. The data obtained from the experiments was analyzed using Taguchi Method and Pareto ANOVA to obtain optimal process parameters. The values obtained after the analyses were tested on turning three more samples to verify the integrity of the results. By the optimization of CNC process parameters, considerable amount of refinements were obtained for both tool wear and surfa...

This paper investigates the feasibility to achieve grinding-hardening in a plunge cylindrical grinding process. To understand the mechanisms, a temperature-dependent finite element heat transfer model incorporating a triangular moving heat source was developed to describe the temperature field, thus to predict the thickness of the grinding-hardened layer. The analysis carried out included the variation effect of depth of cut caused by the change in wheel-workpiece engagement. The model was applied on quenchable steel 1045 and the analysis was verified experimentally. It was shown that the heating cycle in plunge cylindrical grinding is the result of consecutive heating and cooling processes, varying from location to location in a workpiece. The ratio of the workpiece speed to the infeed rate plays an important role in the heat treatment cycle.

It is vital to anticipate the durability of drill bits for all drilling operations to prolong the drilling processes and reducing economic losses. Many attempts have been made to handle this issue by assessing the parameter of specific energy of the bits generated during drilling along with well logs and geophysical analyses. Although these techniques could provide acceptable precautions of the dullness of bit cutters, lack of consideration of material properties of the rock and the bit is their main shortcoming which could result in misleading interpretations. The present study deals with the development of a wear model of Tri-cone bits based on the concept of three body abrasive wear taking into account two main factors , rock hardness and the hardness of the materials forming the Tri-cone drill bit. Other parameters that have significant effect are also considered such as weight on bit, penetration rate, rotation speed and the required time to penetrate an interval depth. In this research, the bit wear quantified by the new developed model is compared with the in-situ dullness of the drill bit for a number of wells being excavated in southern Iraq, where a reasonable agreement was observed. The present work could be extended on other oil wells and applied on other types of drill bits to confirm the validation of the new model.

Every day scientists are developing new materials and for these material, we need economical and efficient machining process. Optimum machining parameters are of great concern in manufacturing environments, where economy of machining operation plays a key role in competitiveness in the market. The present work deals with the review of optimization of milling process parameters.

This paper presents an analysis of the excavation forces involved in the cutting action and in the friction of a cutter/rock contact. A vertical lathe-type device provided data on the forces applied on a single cutter under dry excavation conditions. A cutting device was used to perform cutting experiments with unworn and worn cutters. A tribometer was used to perform friction tests on the cutters wear flat previously realized with the vertical lathe. The experiments display results conform to the literature as the nondependence of the cutting coefficient to the rock properties. Then, this study focuses on the cutting forces and explains that these forces include a component of rock shearing and impact friction. The impact friction is induced by the interaction between ejected rock particles and the cutting active area. The evidence of this impact friction is then brought by the formation of an eroded zone on the cutting active area.