The Assessment of Cutting Force with Taguchi Design in Medium Carbon Steel–Applied Spheroidization Heat Treatment

In this study, the analysis of cutting forces on medium carbon AISI 1050—to which different spheroidization heat treatments were applied—was conducted by the mixed-level Taguchi orthogonal experiment design method. In the experiments, besides the parameters of feed rate, depth of cut and cutting speed having effect on cutting forces as a factor in orthogonal design, the spheroidization time and temperature parameters were also used. By the performed orthogonal experiment design method, the values of cutting forces were estimated using the five-factor, two- and three-leveled Taguchi L36 (22 × 33) mixed orthogonal experiment design method. The effectiveness of the machining parameters on the cutting force was revealed by performing analysis of variance test. Moreover, the effectiveness rates of the parameters were also determined in the study as per the signal noise rates. Consequently, it has been observed that the feed rate is more effective on the cutting forces compared to other parameters.

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Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

Materials Science Forum ◽

10.4028/www.scientific.net/msf.836-837.168 ◽

2016 ◽

Vol 836-837 ◽

pp. 168-174 ◽

Cited By ~ 2

Author(s):

Ying Fei Ge ◽

Hai Xiang Huan ◽

Jiu Hua Xu

Keyword(s):

Cutting Force ◽

Feed Rate ◽

Cutting Forces ◽

High Speed ◽

Volume Fraction ◽

Cutting Temperature ◽

Cutting Speed ◽

Depth Of Cut ◽

High Speed Milling ◽

Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

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Taguchi Method Based Experiments of Titanium TC11 Flank Milling Parameters

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.407-408.608 ◽

2009 ◽

Vol 407-408 ◽

pp. 608-611 ◽

Cited By ~ 3

Author(s):

Chang Yi Liu ◽

Cheng Long Chu ◽

Wen Hui Zhou ◽

Jun Jie Yi

Keyword(s):

Surface Roughness ◽

Cutting Force ◽

Feed Rate ◽

High Speed ◽

Cutting Temperature ◽

Cutting Speed ◽

Flank Milling ◽

Depth Of Cut ◽

Machining Parameters ◽

Mill Machining

Taguchi design methodology is applied to experiments of flank mill machining parameters of titanium alloy TC11 (Ti6.5A13.5Mo2Zr0.35Si) in conventional and high speed regimes. This study includes three factors, cutting speed, feed rate and depth of cut, about two types of tools. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of cutting force, cutting temperature and surface roughness. The analysis of result shows that the factors combination for good surface roughness, low cutting temperature and low resultant cutting force are high cutting speed, low feed rate and low depth of cut.

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Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Metals ◽

10.3390/met10060840 ◽

2020 ◽

Vol 10 (6) ◽

pp. 840 ◽

Cited By ~ 3

Author(s):

Rashid Ali Laghari ◽

Jianguang Li ◽

Mozammel Mia

Keyword(s):

Mathematical Model ◽

Cutting Force ◽

Feed Rate ◽

Cutting Forces ◽

Desirability Function ◽

Interactive Effect ◽

Cutting Speed ◽

Experimental Results ◽

Machining Process ◽

Depth Of Cut

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

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Performance Optimization of High Specific Speed Centrifugal Pump Based on Orthogonal Experiment Design Method

Processes ◽

10.3390/pr7100728 ◽

2019 ◽

Vol 7 (10) ◽

pp. 728 ◽

Cited By ~ 1

Author(s):

Li ◽

Ding ◽

Shen ◽

Jiang

Keyword(s):

Centrifugal Pump ◽

Performance Optimization ◽

Design Method ◽

Orthogonal Experiment ◽

Three Dimensional ◽

Experiment Design ◽

Three Dimensional Model ◽

Pump Design ◽

Orthogonal Experiment Design ◽

Specific Speed

A high specific speed centrifugal pump is used in the situation of large flow and low head. Centrifugal pump parameters need to be optimized in order to raise its head and efficiency under off-design conditions. In this study, the orthogonal experiment design method is adopted to optimize the performance of centrifugal pump basing on three parameters, namely, blade outlet width b2, blade outlet angle β2 and blade wrap angle φ. First, the three-dimensional model of the centrifugal pump is established by CFturbo and SolidWorks. Then nine different schemes are designed by using orthogonal table, and numerical simulation is carried out in CFX15.0. The final optimized combination of parameters is b2 = 24 mm, β2 = 24°, φ = 112°. Under the design condition, the head and efficiency of the optimized centrifugal pump are appropriately improved, the increments of which are 0.74 m and 0.48%, respectively. However, the efficiency considerably increases at high flow rates, with an increase of 6.9% at 1.5 Qd. The anti-cavitation performance of the optimized centrifugal pump is also better than the original pump. The results in this paper can provide references for parameter selection (b2, β2, φ) in the centrifugal pump design.

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PREDICTION OF TANGENTIAL CUTTING FORCE IN END MILLING OF MEDIUM CARBON STEEL BY COUPLING DESIGN OF EXPERIMENT AND RESPONSE SURFACE METHODOLOGY

Journal of Mechanical Engineering ◽

10.3329/jme.v40i2.5350 ◽

1970 ◽

Vol 40 (2) ◽

pp. 95-103 ◽

Cited By ~ 3

Author(s):

Md. Anayet Patwari ◽

A.K.M. Nurul Amin ◽

Waleed F. Faris

Keyword(s):

Response Surface Methodology ◽

Carbon Steel ◽

Cutting Force ◽

Feed Rate ◽

End Milling ◽

Cutting Speed ◽

Cutting Parameters ◽

Medium Carbon Steel ◽

Depth Of Cut ◽

Medium Carbon

The present paper discusses the development of the first and second order models for predicting the tangential cutting force produced in end-milling operation of medium carbon steel. The mathematical model for the cutting force prediction has been developed, in terms of cutting parameters cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). All the individual cutting parameters affect on cutting forces as well as their interaction are also investigated in this study. The second order equation shows, based on the variance analysis, that the most influential input parameter was the feed rate followed by axial depth of cut and, finally, by the cutting speed. Central composite design was employed in developing the cutting force models in relation to primary cutting parameters. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated. The adequacy of the predictive model was verified using ANOVA at 95% confidence level. This paper presents an approach to predict cutting force model in end milling of medium carbon steel using coated TiN insert under dry conditions and full immersion cutting.Keywords: Tangential Cutting Forces; RSM; coated TiN; model.DOI: 10.3329/jme.v40i2.5350Journal of Mechanical Engineering, Vol. ME 40, No. 2, December 2009 95-103

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Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

SN Applied Sciences ◽

10.1007/s42452-021-04689-z ◽

2021 ◽

Vol 3 (7) ◽

Author(s):

Rashid Ali Laghari ◽

Jianguang Li

Keyword(s):

Mathematical Model ◽

Cutting Force ◽

Feed Rate ◽

Cutting Forces ◽

Positive Response ◽

Cutting Speed ◽

Machining Process ◽

Depth Of Cut ◽

Force Model ◽

Sic Particles

Abstract In this study, the proposed experimental and second-order model for the cutting forces were developed through several parameters, including cutting speed, feed rate, depth of cut, and two varying content of SiCp. Cutting force model was developed and optimized through RSM and compared for two different percentages of components SiCp/Al 45% and SiCp/Al 50%. ANOVA is used for Quantitative evaluation, the main effects plot along with the evaluation using different graphs and plots including residual analysis, contour plots, and desirability functions for cutting forces optimization. It provides the finding for choosing proper parameters for the machining process. The plots show that during increment with depth of cut in proportion with feed rate are able to cause increments in cutting forces. Higher cutting speed shows a positive response in both the weight percentage of SiCp by reducing the cutting force because of higher cutting speed increases. A very fractional increasing trend of cutting force was observed with increasing SiCp weight percentages. Both of the methods such as experiment and model-predicted results of SiCp/Al MMC materials were thoroughly evaluated for analyzing cutting forces of SiCp/Al 45%, and SiCp/Al 50%, as well as calculated the error percentages also found in an acceptable range with minimal error percentages. Article Highlights This study focuses on the effect of cutting parameters as well as different percentage of SiC particles on the cutting forces, while comparing the results of both SiC particles such as SiCp/Al 45%, and SiCp/Al 50% the result shows that there isn’t fractional amount of impact on the cutting force with nominal increasing percentages of SiC particles. Cutting speed in machining process of SiCp/Al shows positive response in reducing the cutting forces, however, increasing amount of depth of cut followed by increasing feed rate creates fluctuations in cutting force and thus increases the cutting force in the cutting process. The developed RSM mathematical model which is based on the box Behnken design show excellent competence for predicting and suggesting the machining parameters for both SiCp/Al 45%, and SiCp/Al 50% and the RSM mathematical model is feasible for optimization of the machining process with good agreement to experimental values.

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Prediction of Cutting Force in Turning Process by Using Artificial Neural Network

Al-Khwarizmi Engineering Journal ◽

10.22153/kej.2020.04.002 ◽

2020 ◽

Vol 16 (2) ◽

pp. 34-46

Author(s):

Marwa Qasim Ibraheem

Keyword(s):

Neural Network ◽

Experimental Data ◽

Artificial Neural Network ◽

Cutting Force ◽

Cutting Forces ◽

Cutting Speed ◽

Depth Of Cut ◽

Machining Parameters ◽

Turning Operation ◽

Artificial Neural

Cutting forces are important factors for determining machine serviceability and product quality. Factors such as speed feed, depth of cut and tool noise radius affect on surface roughness and cutting forces in turning operation. The artificial neural network model was used to predict cutting forces with related to inputs including cutting speed (m/min), feed rate (mm/rev), depth of cut (mm) and work piece hardness (Map). The outputs of the ANN model are the machined cutting force parameters, the neural network showed that all (outputs) of all components of the processing force cutting force FT (N), feed force FA (N) and radial force FR (N) perfect accordance with the experimental data. Twenty-five samples of experimental data were used, including nineteen to train the network. Moreover six other experimental tests were implemented to test the network. The study concludes that ANN was a dependable and precise method for predicting machining parameters in CNC turning operation.

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A Novel MCDM Approach for Simultaneous Optimization of some Correlated Machining Parameters in Turning of CP-Titanium Grade 2

International Journal of Engineering Research in Africa ◽

10.4028/www.scientific.net/jera.22.94 ◽

2016 ◽

Vol 22 ◽

pp. 94-111 ◽

Cited By ~ 8

Author(s):

Akhtar Khan ◽

Kalipada Maity

Keyword(s):

Cutting Force ◽

Feed Rate ◽

Pure Titanium ◽

Cutting Speed ◽

Simultaneous Optimization ◽

Depth Of Cut ◽

Machining Parameters ◽

Titanium Grade ◽

The Impact ◽

Machining Parameter

The present work explores the application of a novel Multi-Criteria Decision Making (MCDM) based approach known as VIKOR analysis combined with Taguchi technique for simultaneous optimization of some correlated cutting variables in turning of commercially pure titanium grade 2 using uncoated carbide inserts. The experiments have been carried out according to Taguchi’s L27 orthogonal array. Three input variables viz. cutting speed, feed rate and depth of cut have been taken at three different levels. The impact of these cutting variables on cutting force, surface quality and material removal rate has been investigated. The optimal combination of machining parameters has been evaluated to minimize the cutting force and to maximize the surface finish and production rate using MCDM based VIKOR analysis method. ANOVA (analysis of variance) test has been performed to determine the most influencing cutting variable on overall quality measure i.e. VIKOR index (Qi). The optimal setting of machining variables has been shown using main effects plot for S/N ratio for Qi. The results of ANOVA exhibit that the cutting speed is the governing machining parameter followed by feed rate on overall quality index (Qi). The minimum (desirable) value of Qi is achieved at the parametric combination of v3-f1-d3 i.e. cutting speed (110 m/min), feed rate (0.08 mm/rev) and depth of cut (0.4 mm) respectively. The feasibility of the proposed methodology has been verified by conducting a confirmation test.

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