Development of an EN8 Steel Stepped Rotor by a Novel Engraving Milling Technique
Abstract
:1. Introduction
2. Fabrication and Experimental Details
2.1. Materials and Methods
2.2. Procedure of Manufacturing the Small-Sized Stepped Rotor
- Preparation of the blanks with a 25 mm diameter from the EN8 steel round bar using a manual lathe machine tool.
- The next step is the preparation of the stepped blank with a hub, bind bore, and screw hole from the blank by turning and drilling machining operations.
- After the preparation of the stepped blank, the next step is the preparation of a two-dimensional layout (Figure 3) of the semi-open-type stepped rotor with the help of AutoCAD 2023.
- The next step is the conversion of the AutoCAD-prepared two-dimensional geometrical layout of the rotor into a G-code and M-code part program.
- The next step is transferring the prepared part program to the CNC engraving milling machine with the help of a disk or pen drive.
- The next step is the referencing of the CNC engraving milling machine. CNC referencing is compulsory before starting the machining process in each experimental run.
- After that, the next step is clamping the designed fixture and V block on the worktable of the CNC engraving milling machine to firmly hold the stepped blank using screws.
- The next step is ensuring the firm and appropriate positioning of the prepared stepped blank in the V block with the help of the dial gauge, as shown in Figure 4a. Minor variations in the positioning of the blank and flatness of the top surface significantly increase the noise and tool wear and reduce the dimensional accuracy as well as the surface quality of the manufactured turbine.
- The next step is the setting of the Z height of the cutting tool just above the top face of the blank with the help of a special gauge for safety purposes, as shown in Figure 4b. It prevents the cutting tool from coming in direct contact with the blank for machining. The movement of the cutting tool will be stopped at this height before starting the machining to avoid any risk of damage due to program or operator error.
- The window-based Mac 3 software is incorporated with the used CNC-EMM approach to read the part program and direct the cutting tool movement on the desired path of the part program.
- Machining initiates with cutting and preparing the exact periphery as per the part program shown in Figure 4c. Cutting tools rotate in a clockwise direction.
- The small-sized stepped rotor is manufactured into three machining stages, known as the rough cut (RC), semi-finished cut (SFC), and finished cut (FC). A different part program was prepared for each stage.
- The cutting tool rotates and moves in a clockwise direction during the engraving blade. The layout of the rotor blade and the direction of the tool path are shown in Figure 5. In each movement, the tool removes 50 µm of material in downward Z directions. Thus, the tool repeats the same path a hundred times to engrave a single blade with 5 mm height.
- Figure 6 shows the whole process sequence and engraving of the rotor blades by CNC-EMM.
- After cutting the steeped rotor, the next step is to perform measurements of the average surface roughness and capture micrographs of the manufactured rotor blade using a field-emission scanning electron microscope (FE-SEM).
2.3. Experimentation and Measurements
3. Results and Discussion
- The developed linear model of average roughness ‘Ra’ is significant as their ‘Prob > F’ (i.e., p values) is less than 0.05.
- Values of ‘Prob > F’ that are less than 0.05 indicate that the respective model terms are significant. Therefore, feed ‘f’ and plunge feed ‘Pf’ were found to be statistically significant for average roughness ‘Ra’.
- The F-value of 10.45 for average roughness ‘Ra’ suggests that the model is significant.
- The lack of fit F-values are non-significant relative to the pure error for average roughness ‘Ra’. The non-significant lack of fit is good and indicates that the developed model correctly fits the experimental data.
- Adequate precision indicates the signal-to-noise ratio, and its value being greater than four indicates an adequate signal. The value of adequate precision for Ra is 10.08.
- The residuals of each experiment are concentrated around the mean line (Figure 7). Therefore, they exhibit a normal distribution.
- The developed empirical equation 1 is linear (i.e., without square terms or interaction terms) and can be used for the future prediction of the values of average roughness ‘Ra’.
4. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
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Expt. No. | CNC-EMM Variable Parameters | Response/Performance Measure | ||
---|---|---|---|---|
Rotational Speed ‘SR’ (rpm) | Feed ‘f’ (mm/min) | Plunge Feed ‘Pf’ (mm/min) | Average Roughness ‘Ra’ (µm) | |
1 | 5500 | 800 | 125 | 0.11 |
2 | 5500 | 900 | 150 | 0.29 |
3 | 5500 | 900 | 100 | 0.15 |
4 | 5500 | 1000 | 125 | 0.45 |
5 | 6000 | 800 | 150 | 0.38 |
6 | 6000 | 800 | 100 | 0.14 |
7 | 6000 | 900 | 125 | 0.3 |
8 | 6000 | 900 | 125 | 0.29 |
9 | 6000 | 1000 | 100 | 0.17 |
10 | 6000 | 1000 | 150 | 0.44 |
11 | 6500 | 800 | 125 | 0.13 |
12 | 6500 | 900 | 150 | 0.47 |
13 | 6500 | 900 | 100 | 0.2 |
14 | 6500 | 1000 | 125 | 0.55 |
Source | Sum of Squares | DF | Mean Squares | F-Value | p-Value (Prob > F) | Remarks |
---|---|---|---|---|---|---|
Model | 0.21 | 3 | 0.070 | 10.45 | 0.0020 | Significant |
Rotating speed ‘SR’ | 0.015 | 1 | 0.015 | 2.27 | 0.1629 | Not significant |
Feed ‘f’ | 0.090 | 1 | 0.090 | 13.39 | 0.0044 | Significant |
Plunge feed ‘Pf’ | 0.11 | 1 | 0.11 | 15.68 | 0.0027 | Significant |
Residual | 0.067 | 10 | 6.747 × 10−3 | |||
Lack of Fit | 0.067 | 9 | 7.491 × 10−3 | 149.82 | 0.0633 | Not significant |
Pure Error | 5.000 × 10−5 | 1 | 5.000 × 10−5 | |||
Cor Total | 0.28 | 13 |
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Chaubey, S.K.; Gupta, K. Development of an EN8 Steel Stepped Rotor by a Novel Engraving Milling Technique. Materials 2024, 17, 1588. https://doi.org/10.3390/ma17071588
Chaubey SK, Gupta K. Development of an EN8 Steel Stepped Rotor by a Novel Engraving Milling Technique. Materials. 2024; 17(7):1588. https://doi.org/10.3390/ma17071588
Chicago/Turabian StyleChaubey, Sujeet Kumar, and Kapil Gupta. 2024. "Development of an EN8 Steel Stepped Rotor by a Novel Engraving Milling Technique" Materials 17, no. 7: 1588. https://doi.org/10.3390/ma17071588