Multi-response optimization in environment friendly turning of AISI 304 austenitic stainless steel

2019 ◽  
Vol 15 (3) ◽  
pp. 538-558 ◽  
Author(s):  
Talwinder Singh ◽  
J.S. Dureja ◽  
Manu Dogra ◽  
Manpreet S. Bhatti
Keyword(s):  
Stainless Steel ◽  
Flank Wear ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Aisi 304 Stainless Steel ◽  
Environment Friendly ◽  
Aisi 304 ◽  
Tool Flank Wear ◽  
Content Type

Purpose The purpose of this paper is to investigate the influence of turning parameters such as cutting speed, feed rate and depth of cut on tool flank wear and machined surface quality of AISI 304 stainless steel during environment friendly turning under nanofluid minimum quantity lubrication (NMQL) conditions using PVD-coated carbide cutting inserts. Design/methodology/approach Turning experiments are conducted as per the central composite rotatable design under the response surface methodology. ANOVA and regression analysis are employed to examine significant cutting parameters and develop mathematical models for VB (tool flank wear) and Ra (surface roughness). Multi-response desirability optimization approach is used to investigate optimum turning parameters for simultaneously minimizing VB and Ra. Findings Optimal input turning parameters are observed as follows: cutting speed: 168.06 m/min., feed rate: 0.06 mm/rev. and depth of cut: 0.25 mm with predicted optimal output response factors: VB: 106.864 µm and Ra: 0.571 µm at the 0.753 desirability level. ANOVA test reveals depth of cut and cutting speed-feed rate interaction as statistically significant factors influencing tool flank wear, whereas cutting speed is a dominating factor affecting surface roughness. Confirmation tests show 5.70 and 3.71 percent error between predicted and experimental examined values of VB and Ra, respectively. Research limitations/implications AISI 304 is a highly consumed grade of stainless steel in aerospace components, chemical equipment, nuclear industry, pressure vessels, food processing equipment, paper industry, etc. However, AISI 304 stainless steel is considered as a difficult-to-cut material because of its high strength, rapid work hardening and low heat conductivity. This leads to lesser tool life and poor surface finish. Consequently, the optimization of machining parameters is necessary to minimize tool wear and surface roughness. The results obtained in this research can be used as turning database for the above-mentioned industries for attaining a better machined surface quality and tool performance under environment friendly machining conditions. Practical implications Turning of AISI 304 stainless steel under NMQL conditions results in environment friendly machining process by maintaining a dry, healthy, clean and pollution free working area. Originality/value Machining of AISI 304 stainless steel under vegetable oil-based NMQL conditions has not been investigated previously.

Optimization of flank wear and surface roughness during turning of AISI 304 stainless steel using the Taguchi method

2020 ◽  
Vol 62 (9) ◽  
pp. 957-961
Author(s):  
Nursel Altan Özbek ◽  
Metin İbrahim Karadag ◽  
Onur Özbek
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Taguchi Method ◽  
Feed Rate ◽  
Flank Wear ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304

Abstract This paper presents the effect of cutting tool, cutting speed and feed rate on the flank wear and surface roughness of austenitic stainless steel (AISI 304) during wet turning. Turning tests were designed based on the Taguchi method (L18). An orthogonal array, the signal-to-noise ratio (S/N) and the ANOVA were used to investigate the machinability of AISI 304 stainless steel with PVD and CVD coated tungsten carbide inserts. As a result of ANOVA, it was found that the feed rate was the most effective parameter on both flank wear and surface roughness.

Magnetic Damping in Turning of Stainless Steel AISI 304 for the Reduction of Machining Vibration and Tool Wear

2015 ◽  
Vol 1115 ◽  
pp. 100-103
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Siti Aminatuzzuhriyah B. Haji Subir ◽  
Fawaz Mohsen Abdullah
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Flank Wear ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Aisi 304 ◽  
Excited Vibration ◽  
Coated Carbide

Chatter is a type of intensive self-excited vibration commonly encountered in machining. It reduces productivity and precision, and is more noticeable in the machining of difficult-to-cut alloys like hardened steel. In such cases chatter causes excessive tool wear, especially flank wear, which in turn affects the stability of the cutting edge leading to premature tool failure, poor surface finish, and unsatisfactory machining performance. Nowadays, however, the demand is for fine finish, high accuracy, and low operation costs. Therefore, any technique which significantly reduces chatter is profitable for the industry. This paper demonstrates the viability and effectiveness of a novel chatter control strategy in the turning of (AISI 304) stainless steel by using permanent bar magnets. Reduction in chatter and corresponding tool flank wear are compared from results for both undamped and magnetically damped turning using coated carbide inserts. Special fixtures and keyway were made from mild steel in order to affix the magnets on the lathe’s carriage. The two ferrite magnets (1500 Gauss each) were placed below and beside the tool shank for damping from Z and X directions, respectively. Response surface methodology (RSM) was used to design the experimental runs in terms of the three primary cutting parameters: cutting speed, feed, and depth of cut. A Kistler 50g accelerometer measured the vibrations. The data was subsequently processed using DasyLab (version 6) software. The tool wear was measured using scanning electron microscope (SEM). Results indicate that this damping setup can reduce vibration amplitude by 47.36% and tool wear by 63.85%, on average. Thus, this technique is a simple and economical way of lowering vibration and tool wear in the turning of stainless steel.

scholarly journals Finite element simulation and regression modeling of machining attributes on turning AISI 304 stainless steel

2021 ◽  
Vol 8 ◽  
pp. 24
Author(s):  
A. Mathivanan ◽  
M.P. Sudeshkumar ◽  
R. Ramadoss ◽  
Chakaravarthy Ezilarasan ◽  
Ganesamoorthy Raju ◽  
...  
Keyword(s):  
Finite Element ◽  
Stainless Steel ◽  
Cutting Force ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Computational Time ◽  
Depth Of Cut ◽  
Aisi 304 Stainless Steel ◽  
Machining Processes ◽  
Aisi 304

To-date, the usage of finite element analysis (FEA) in the area of machining operations has demonstrated to be efficient to investigate the machining processes. The simulated results have been used by tool makers and researchers to optimize the process parameters. As a 3D simulation normally would require more computational time, 2D simulations have been popular choices. In the present article, a Finite Element Model (FEM) using DEFORM 3D is presented, which was used to predict the cutting force, temperature at the insert edge, effective stress during turning of AISI 304 stainless steel. The simulated results were compared with the experimental results. The shear friction factor of 0.6 was found to be best, with strong agreement between the simulated and experimental values. As the cutting speed increased from 125 m/min to 200 m/min, a maximum value of 750 MPa stress as well as a temperature generation of 650 °C at the insert edge have been observed at rather higher feed rate and perhaps a mid level of depth of cut. Furthermore, the Response Surface Methodology (RSM) model is developed to predict the cutting force and temperature at the insert edge.

Effects of post-weld heat treatments on the microstructure, mechanical and corrosion properties of gas metal arc welded 304 stainless steel

2020 ◽  
Vol 17 (1) ◽  
pp. 87-96 ◽  
Author(s):  
Taiwo Ebenezer Abioye ◽  
Igbekele Samson Omotehinse ◽  
Isiaka Oluwole Oladele ◽  
Temitope Olumide Olugbade ◽  
Tunde Isaac Ogedengbe
Keyword(s):  
Stainless Steel ◽  
Welded Joint ◽  
Grain Structure ◽  
304 Stainless Steel ◽  
Aisi 304 Stainless Steel ◽  
Corrosion Properties ◽  
Aisi 304 ◽  
Content Type ◽  
Post Annealing ◽  
Weld Heat

Purpose The purpose of this study is to determine the effects of post-annealing and post-tempering processes on the microstructure, mechanical properties and corrosion resistance of the AISI 304 stainless steel gas metal arc weldment. Design/methodology/approach Gas metal arc welding of AISI 304 stainless steel was carried out at an optimized processing condition. Thereafter, post-annealing and post-tempering processes were performed on the weldment. The microstructure, mechanical and electrochemical corrosion properties of the post-weld heat treated samples, as compared with the as-welded, were investigated. Findings The as-welded joint was characterized with sub-granular grain structure, martensite formation and Cr-rich carbides precipitates. This made it harder than the post-annealed and post-tempered joints. Because of slower cooling in the furnace, the post-annealed joint contained Cr-rich carbides precipitates. However, the microstructure of the post-tempered joint is more refined and significantly devoid of the carbide precipitates. Post-tempering process improved the elongation (∼23%), tensile (∼10%) and impact (∼31%) strengths of the gas metal arc AISI 304 stainless steel weldment, while post-annealing process improved the elongation (∼20%) and impact strength (∼72%). Owing to the refined grain structure and significant elimination of the Cr-rich carbide precipitates at the joint, the post-tempered joint exhibited better corrosion resistance in 3.5 Wt.% NaCl solution than the post-annealed and the as-welded joints. Originality/value The appropriate post-weld heat treatment that enhances microstructural homogeneity and quality of the AISI 304 gas metal arc welded joint was determined.

Fabrication of Mn–Co–Ni-coated layer on AISI 304 stainless steel for protection of Cr evaporation by electroplating process

2019 ◽  
Vol 66 (5) ◽  
pp. 689-694
Author(s):  
Kattareeya Taweesup ◽  
Sirirat Khotsombat ◽  
Kongkwan Chubanjong ◽  
Siraphatsorn Wutthiseelanon
Keyword(s):  
Stainless Steel ◽  
Oxidation Resistance ◽  
Coating Layer ◽  
304 Stainless Steel ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304 ◽  
Content Type ◽  
Coated Layer ◽  
Electroplating Process ◽  
Cr Evaporation

Purpose This study aims to improve the oxidation resistance of SS304 stainless steel by fabrication of Mn–Co–Ni-coated layer. Mn–Co–Ni coating with the thickness ranging from 1.76 to 8.50 micron were prepared by electroplating process on SS304 stainless steel, focusing on the plating time which play significant roles on the performance of the film thickness and crystallize size. Design/methodology/approach Mn–Co–Ni coating layer was applied on AISI 304 stainless steel using electroplating process with solution consisted of cobalt sulfate (CoSO4), manganese sulfate (MnSO4) and nickel sulfate (NiSO4). Variation of Mn–Co–Ni coating, the morphology of the film and oxidation kinetics were investigated by using scanning electron microscopy and x-ray diffraction analysis. Furthermore, the sample with coating layer was tested by oxidation and Cr evaporation test. Findings From the formation parameter due to plating time for the conversion coating, it was found that plating time plays significant roles in the performance of the coating thickness and crystallize size. The crystallize size has an inverse relation to the full width at half maximum of diffraction peak. Film thickness higher than 6.07 micron causes a decrease in oxidation resistance and an increase of Cr evaporation from SS304 stainless steel. In this study, the Mn–Co–Ni coating with a thickness lower than 3.77 micron showed coating protection of oxidation better than SS304 substrate. Originality/value The effect of coating thickness was investigated to understand the properties of the coating. Furthermore, oxidation and Cr evaporation test were applied to evaluate the oxidation resistance of the coating layer.

scholarly journals Machining Performance Investigation of AISI 304 Austenitic Stainless Steel under Different Turning Environments

2018 ◽  
Vol 15 (4) ◽  
pp. 5837-5862
Author(s):  
Talwinder Singh ◽  
J. S. Dureja ◽  
Manu Dogra ◽  
Manpreet S. Bhatti
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Flank Wear ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Strong Basis ◽  
Aisi 304 ◽  
Tool Flank Wear ◽  
304 Austenitic Stainless Steel ◽  
Coated Carbide

Environment friendly machining calls for minimizing the use of cutting fluids to reduce their negative impact on environment and operator health. Present experimental work is aimed to investigate machining performance of AISI 304 austenitic stainless steel with PVD coated carbide tool under different turning environments viz. dry, flooded and nanofluid minimum quantity lubrication (NF-MQL). Optimum turning parameters obtained through desirability function optimisation are found as: cutting speed of 160.67 m/min, feed of 0.06 mm/rev and depth of cut of 0.25 mm with predicted tool flank wear of 100.001 μm and surface roughness of 0.509 μm at 0.808 desirability level. Confirmation tests show 3.22% and 3.41% error between predicted and experimental values of Vb and Ra, respectively. Present study has established the superiority of NF-MQL machining over dry and flooded machining. The most salient achievement of this investigation is the reduction of tool flank wear by 32.26% under NF-MQL machining compared to dry machining and 9.68% compared to flooded machining conditions. Similarly, NF-MQL exhibits improvement in surface finish by 34.72% and 7.59% over dry and flooded coolant environments respectively, thus providing a strong basis to replace flooded coolant machining for sustainable future.

scholarly journals Influence of cutting speed on dry machinability of AISI 304 stainless steel

2020 ◽  
Author(s):  
Surjeet Singh Bedi ◽  
Sarthak Prasad Sahoo ◽  
Bikkina Vikas ◽  
Saurav Datta
Keyword(s):  
Stainless Steel ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304

Investigation of mechanical properties and parametric optimization of the dissimilar GTAW of AISI 304 stainless steel and low carbon steel

2018 ◽  
Vol 15 (5) ◽  
pp. 584-591 ◽  
Author(s):  
Tunde Isaac Ogedengbe ◽  
Taiwo Ebenezer Abioye ◽  
Augusta Ijeoma Ekpemogu
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
Carbon Steel ◽  
Low Carbon Steel ◽  
304 Stainless Steel ◽  
Low Carbon ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304 ◽  
Content Type ◽  
Weld Region

Purpose The purpose of this study is to conduct gas tungsten arc dissimilar welding of AISI 304 stainless steel and low carbon steel within a process window so as to investigate the effects of current, speed and gas flow rate (GFR) on the microstructure and mechanical properties of the weldments. Design/methodology/approach The welding experiment was carried out at different combinations of parameters using WN-250S Kaierda electric welding machine. A combination of scanning electron microscopy and energy dispersive X-ray spectroscopy was used to examine the microstructure of the weldments. Micro-hardness and tensile tests were performed using Vickers hardness tester and Instron universal testing machine, respectively. ANOVA was used to analyze the significance of the parameters on the mechanical properties. Findings The microstructure of the weld region is characterized with dendritic structure with the existence of ferrite and austenite phases. The utilized parameters show significant effects on the ultimate tensile strength (UTS) of the weldments. The current and GFR were found to be the most and least significant factors, respectively. Both the grain size and weld penetration contributed to the UTS of the weldments. The UTS (427-886 MPa) increased with decreasing current and welding speed. In all samples, the weld region exhibited higher hardness (297-396 HV) than the HAZ in the base metals (maximum of 223 Â ± 6 HV). All the three factors show significant effect with the welding speed contributing mostly to the hardness of the weld region. Originality/value The parametric combination that gives the optimum mechanical performance of the dissimilar gas tungsten arc weldments of AISI 304 stainless steel and low carbon steel was established.

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