Machinability Investigation of HSLA Steel in Hard Turning with Coated Ceramic Tool: Assessment, Modeling, Optimization and Economic Aspects

2019 ◽  
Vol 18 (04) ◽  
pp. 625-655 ◽  
Author(s):  
Asutosh Panda ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ceramic Tool ◽  
Life Estimation

The present study addresses the machinability investigation in finish dry hard turning of high strength low alloy steel with coated ceramic tool by considering cutting speed, feed and depth of cut as machining parameters. The technological parameters like surface roughness, flank wear, chip morphology and economical feasibility have been considered to investigate the machinability performances. Twenty seven set of trials according to full factorial design of experiments are performed and analysis of variance, multiple regression method, Taguchi method, desirability function approach and finally Gilbert’s approach are subsequently applied for parametric influence study, mathematical modeling, multi-response optimization, tool life estimation and economic analysis. Results indicated that feed and cutting speed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness and tool flank wear is considered. Abrasions, adhesion followed by plastic deformation have been observed to be the principal wear mechanism for tool life estimation and observed tool life for coated ceramic insert is 47[Formula: see text]min under optimum cutting conditions. The total machining cost per part is ensued to be lower ($0.29 only) as a consequence of higher tool life, reduction in downtime and enhancement in savings, which finds economical benefits in hard turning. The current work demonstrates the substitution of conventional, expensive and slow cylindrical grinding process, and proposes the most expensive CBN tool alternative using coated ceramic tools in hard turning process considering techno-economical and ecological aspects.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

Machining characteristics of Inconel 718 under several cutting conditions based on Taguchi method

2012 ◽  
Vol 227 (9) ◽  
pp. 1889-1897 ◽  
Author(s):  
R Thirumalai ◽  
JS Senthilkumaar ◽  
P Selvarani ◽  
S Ramesh
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Flank Wear ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machining Parameters ◽  
Dry Machining ◽  
Noise Factors

Extensive researchers have conducted several experiments in the past for selecting the optimum parameters in machining nickel based alloy – Inconel 718. These experiments conducted so far are dealt with dry machining and flooded coolant machining of nickel alloy Inconel 718. In this research study, the usage of refrigerated coolant is also dealt with and it is compared with dry machining and flooded coolant machining. Cutting speed, feed and depth of cut are considered as the machining parameters. The effectiveness of the refrigerated coolant in machining the heat resistant super alloy material Inconel 718 with respect to these machining parameters are described in this article. The machinability studies parameters were generated with surface roughness and flank wear. The performance of uncoated carbide cutting tool was investigated at various cutting condition under dry, flooded coolant and refrigerated coolant machining. The relationship between the machining parameters and the performance measures were established and using analysis of variance significant machining parameters determined. This article made an attempt to Taguchi optimization technique to study the machinability performances of Inconel 718. Taguchi approach is an efficient and effective experimental method in which a response variable can be optimized, given various control and noise factors, using fewer experiments than a factorial design. Taguchi’s optimization analysis indicates that the factors level, its significance to influence the surface roughness and flank wear for the machining processes. Confirmation tests were conducted at an optimal condition to make a comparison between the experimental results foreseen from the mentioned correlations.

Technological Investigation of Effect of Machining Parameter on Tool Life

2020 ◽  
Vol 22 (4) ◽  
pp. 41-53
Author(s):  
Manojkumar Sheladiya ◽  
◽  
Shailee Acharya ◽  
Ghanshyam Acharya ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Numerical Control ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Time ◽  
Machining Parameter

Introduction. The machinability is typical criteria to be investigated and different authors suggested different parameters describing its quantification. Different parameters i. e. speed, feed, depth of cut, tool work-piece combination, machine types and its condition, cutting fluid, machinist expertise, etc. are contributing directly to the tool life. The selection of the tool for the machining impacts greatly on the economic viability of the machining in terms of energy usage and tooling costs. The method of investigation. The current research emphasis mainly on tool life investigation when machining the mild steel specimens ISRO 50, BIS 1732:1989 at constant cutting speed i.e. 200 m / min. In the industries the mild steel material is commonly used for various products manufacturing. Considering the high demands on productivity and surface finish, machining at 200 m / min is the preferred. The computerized numerical control machine (CNC DX-150) is used for the turning. The four corner insert (TNMG 120408) is used for different machining times i.e. 10, 15, 20 and 25 minutes respectively. The flank wear of the tool is measured with calibrated optical microscope. The temperature of the tool corner during machining is continuously measured for possible impact of temperature on bonding properties of the tool insert and impact on red hardness. Results and discussion. The plot of flank wear vs. machining time will give the value of tool life. The other quality output parameter, such as surface roughness, is measured after machining, indicating surface irregularities in root means square value. Efforts have been made to identify the relationship of tool life, machining time, the quantity of metal removed, surface roughness, and tool bit temperature.

scholarly journals Analysis and Optimization of Ceramic Cutting Tool In Hard Turning of EN-31 Using Factorial Design

2012 ◽  
pp. 53-58
Author(s):  
Chetan Darshan ◽  
Lakhvir Singh ◽  
APS Sethi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Analysis Of Variance ◽  
Feed Rate ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Good Surface ◽  
En 31

Manufacturers around the globe persistently looking for the cheapest and quality manufactured machined components to compete in the market. Good surface quality is desired for the proper functioning of the produced parts. The surface quality is influenced by cutting speed, feed rate and depth of cut and many other parameters. In the present study attempt has been made to evaluate the performance of ceramic inserts during hard turning of EN-31 steel. The analysis of variance is applied to study the effect of cutting speed, feed rate and depth of cut on Flank wear and surface roughness. Model is found to be statically significant using regression model, while feed and depth of cut are the factor affecting Flank wear and feed is dominating factors for surface roughness. The analysis of variance was used to analyze the input parameters and there interactions during machining. The developed model predicted response factor at 95% confidence level.

scholarly journals Optimization and Analysis of Surface Roughness, Flank Wear and 5 Different Sensorial Data via Tool Condition Monitoring System in Turning of AISI 5140

Sensors ◽  
2020 ◽  
Vol 20 (16) ◽  
pp. 4377 ◽  
Author(s):  
Mustafa Kuntoğlu ◽  
Abdullah Aslan ◽  
Hacı Sağlam ◽  
Danil Yurievich Pimenov ◽  
Khaled Giasin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Feed Rate ◽  
Cutting Speed ◽  
Tool Condition Monitoring ◽  
Depth Of Cut ◽  
Optimization Approach ◽  
Machining Parameters ◽  
Tool Condition ◽  
Condition Monitoring System

Optimization of tool life is required to tune the machining parameters and achieve the desired surface roughness of the machined components in a wide range of engineering applications. There are many machining input variables which can influence surface roughness and tool life during any machining process, such as cutting speed, feed rate and depth of cut. These parameters can be optimized to reduce surface roughness and increase tool life. The present study investigates the optimization of five different sensorial criteria, additional to tool wear (VB) and surface roughness (Ra), via the Tool Condition Monitoring System (TCMS) for the first time in the open literature. Based on the Taguchi L9 orthogonal design principle, the basic machining parameters cutting speed (vc), feed rate (f) and depth of cut (ap) were adopted for the turning of AISI 5140 steel. For this purpose, an optimization approach was used implementing five different sensors, namely dynamometer, vibration, AE (Acoustic Emission), temperature and motor current sensors, to a lathe. In this context, VB, Ra and sensorial data were evaluated to observe the effects of machining parameters. After that, an RSM (Response Surface Methodology)-based optimization approach was applied to the measured variables. Cutting force (97.8%) represented the most reliable sensor data, followed by the AE (95.7%), temperature (92.9%), vibration (81.3%) and current (74.6%) sensors, respectively. RSM provided the optimum cutting conditions (at vc = 150 m/min, f = 0.09 mm/rev, ap = 1 mm) to obtain the best results for VB, Ra and the sensorial data, with a high success rate (82.5%).

Prediction models for on-line cutting tool and machined surface condition monitoring during hard turning considering vibration signal

2020 ◽  
Vol 21 (5) ◽  
pp. 520
Author(s):  
Amlana Panda ◽  
Ashok Kumar Sahoo ◽  
Isham Panigrahi ◽  
Arun Kumar Rout
Keyword(s):  
Surface Roughness ◽  
Hard Turning ◽  
Flank Wear ◽  
Pearson Correlation ◽  
Cutting Speed ◽  
Vibration Signal ◽  
Machining Parameters ◽  
Pearson Correlation Coefficient ◽  
Vibration Signals ◽  
Acceleration Amplitude

Turning of hardened steel is an immense issue of interest concerning with machining technology and scientific research. A strategy to analyze vibration signals and its correlation on surface roughness and tool wear has not attracted much breakthrough in research so far in hard machining. Therefore, tool condition monitoring (TCM) study will be definitely worthwhile for the effective application in hard part turning. The current study examines about the online prediction of flank wear and surface roughness monitoring during dry hard turning of AISI 52100 steel (55 ± 1 HRC) utilizing MTCVD multilayer coated carbide insert (TiN/TiCN/Al2O3) considering machining parameters and vibration signals through development of prediction model (MLR and MQR) after studying the Pearson correlation coefficient and test for its accuracy. Pearson correlation coefficient for feed on flank wear is utmost pursued by acceleration amplitude of vibration (Vy) in radial direction, depth of cut and cutting speed. Similarly, acceleration amplitude of vibration followed by cutting speed and feed has strong correlation with surface roughness. MQR model predicts well for responses as percentage of error is quite less and cutting speed is obtained to be the most important parameter for vibration signal. Multiple quadratic regression (MQR) models are observed to be noteworthy, effective and adequate to predict response outputs with regards to the combined effect of machining parameters and vibration signals online. A corrective measure can safely be taken with reasonable degree of accuracy during hard turning.

scholarly journals Development of Surface Roughness in Hard Turning of 100Cr6 Using Mixed Ceramic Cutting Tool with Wiper Geometry and Conventional Geometry

2013 ◽  
Vol 21 (Special-Issue) ◽  
pp. 193-198
Author(s):  
Michaela Samardžiová ◽  
Miroslav Neslušan
Keyword(s):  
Surface Roughness ◽  
Hard Turning ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Hard Machining ◽  
Roughness Parameters ◽  
Ceramic Tool ◽  
Mixed Ceramic

Abstract Hard turning has been applied in machining since the early 1980s. There is an effort to substitute finish grinding by hard machining, because of machining by cutting tool with defined geometry. For machining of hardened steels (up to 45 HRC) are used two different cutting materials. PCBN are used the most for discontinuous machining of hardened steel (up to 63 HRC) and mixed ceramic tools, which are used in the experiment. This paper reports a development of surface roughness parameters when using wiper tool geometry of mixed ceramic tool and conventional geometry of mixed ceramic tool in hard turning. Roughness parameters (Ra, Rz, Rsk, Rku, RSm, Rdq) are measured when changing the feed, depth of cut and cutting speed are constant.

Experimental investigation, modelling and optimization in hard turning of high strength low alloy steel (AISI 4340)

2018 ◽  
Vol 106 (4) ◽  
pp. 404 ◽  
Author(s):  
Asutosh Panda ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Hard Turning ◽  
Research Work ◽  
Cutting Speed ◽  
High Strength ◽  
Depth Of Cut ◽  
Turning Process ◽  
Ceramic Tools ◽  
Aisi 4340

The present study addresses the machinability investigation of high strength low alloy grade AISI 4340 steel with coated ceramic tools on surface roughness, tool wear, and economic analysis by considering the hard turning process parameters such as cutting speed, feed and depth of cut. Twenty seven set of trials according to full factorial design of experiments are conducted. Analysis of variance, multiple regression method, Taguchi method, desirability function approach and Gilbert’s technique are employed for parametric influence study, predictive modelling, response optimization, tool life estimation followed by cost analysis. Results indicated that feed and cutting speed are the most significant and crucial factors for hard turning operation in order to achieve minimum surface roughness of machined component as well as flank wear of cutting tool. Abrasions, adhesion followed by plastic deformation are the key wear mechanisms of coated ceramic insert, resulted 47 min of tool life under optimum cutting conditions and ensued lower total machining cost per part ($ 0.29 only) due to higher tool life, and reduced downtime that justifies cost effectiveness of hard turning. Novelty aspects, the current research work demonstrates the substitution of conventional, expensive and slow cylindrical grinding process, and proposes the most expensive CBN tool alternative using coated ceramic tools in hard turning process from techno-economical and ecological point of views in line with the industrial requirements.

scholarly journals Hard Turning of HSLA Steel with Coated Ceramic Inserts: An Assessment, Modelling, Optimisation and Cost Analysis

2018 ◽  
Vol 15 (4) ◽  
pp. 5890-5913
Author(s):  
A. Panda ◽  
Sudhansu Ranjan Das ◽  
D. Dhupal
Keyword(s):  
Economic Analysis ◽  
Hard Turning ◽  
Desirability Function ◽  
Hsla Steel ◽  
Cutting Speed ◽  
High Strength ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Technological Parameters ◽  
Factorial Design Of Experiments

The present study addresses the machinability investigation in finish dry hard turning of high strength low alloy (HSLA) steel with coated ceramic inserts by considering cutting speed, feed and depth of cut as machining parameters. The technological parameters like surface roughness, flank wear, and economic analysis have been considered to investigate machinability performances. Twenty-seven set of trials according to full factorial design of experiments are conducted, and subsequently, analysis of variance, multiple regression method, Taguchi method, desirability function approach and finally Gilbert’s technique is employed for parametric influence study, mathematical modelling, multi-response optimisation, tool life estimation and economic analysis. Novelty aspects, the current work demonstrates the substitution of conventional, expensive and slow cylindrical grinding process, and proposes the most expensive CBN tool alternative using coated ceramic tools in hard turning process considering techno-economic and ecological aspects, which they are useful and efficient from the industrial point of views.  

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