High-speed machining parametric optimization of 15CDV6 HSLA steel under minimum quantity and flood lubrication

High-speed machining (HSM) maintains a high interest in the preparation of metal parts for optimum results, but with the application of HSM, the sustainability issue becomes important. To overcome the problem, minimum quantity lubrication (MQL) during HSM is one of the innovative and challenging tasks during conventional cutting (milling) to improve quality, productivity, and strength under the umbrella of sustainability. The objective of this research is to achieve sustainable machining by simultaneously optimizing sustainable machining drivers during the HSM of 15CDV6 HSLA steel under MQL and flood lubrication. The response surface methodology has been applied for the development of mathematical models and selecting the best combination of process parameters to optimized responses, i.e. surface roughness, material removal rate, and strength. Optimization associated with sustainability produced compromising optimal results (Min. Ra 0.131 µm, Max. MRR 0.64 cm3/min, and Max. ST 1132 MPa) at the highest cutting speed 270 m/min and the lowest feed rate 0.09 mm/rev and depth of cut 0.15 mm under MQL. The comparative investigation exposed that significant improvement in Ra (1.1-16.6 %) and ST (1.3-2.3 %) of the material using MQL has been witnessed and gives a strong indication that MQL is the best substitute than the flood lubrication. The scientific contribution of the approach is to develop mathematical models under MQL and flood lubrication that will aid practitioners to choose input parameters for desired responses without experimentations. The work would be beneficial in the field of aviation, defense, and aeronautical applications due to the excellent mechanical properties of 15CDV6 HSLA steel.

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A review on some investigations into sustainable machining techniques

E3S Web of Conferences ◽

10.1051/e3sconf/202017002003 ◽

2020 ◽

Vol 170 ◽

pp. 02003

Author(s):

Shrikant Gunjal ◽

Sudarshan Sanap

Keyword(s):

High Speed ◽

Cutting Speed ◽

Minimum Quantity Lubrication ◽

Vital Role ◽

Depth Of Cut ◽

High Speed Machining ◽

Machining Performance ◽

Sustainable Machining ◽

Practical Applications ◽

Cryogenic Technique

Machining plays a crucial role in process of economy through the way it contributes around 5% of the country’s total economy. The method of machining has been changed through the last periods due to the competition within the market to urge more profit and High Speed Machining (HSM) plays the vital role to realize the equivalent. Hence, many researchers are working on reduction of the machining cost and consumption of energy. Hard to cut materials have long list of practical applications, which is the main reason to consider their research and development aspects. Thus, it’s important to review the consequences of process parameters mainly like cutting speed, feed rate and depth of cut so as to determine the correlation with reference to key measuring parameters like tool life, surface roughness and tool wear. The authentication of this approach must be proved in future, using different experimental data as high speed machining leads to extreme machining temperature, sudden tool failure and subsequent adverse effects on overall machining performance in all the aspects. Sustainable machining techniques have the effective answer to avoid the adverse consequences of HSM. This paper emphasizes upon the review of application of various sustainable machining techniques like Minimum Quantity Lubrication (MQL), Cryogenic Technique, and Compressed Gas into the high-speed machining of hard to cut materials. Further, the appliance of vegetable based lubricants is highlighted for better comparison.

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Flank Wear Modelling in High Speed Hard Milling of AISI D2 Steel

International Journal of Engineering Materials and Manufacture ◽

10.26776/ijemm.05.02.2020.03 ◽

2020 ◽

Vol 5 (2) ◽

pp. 50-54

Author(s):

Muataz Al Hazza ◽

Khadijah Muhammad

Keyword(s):

Statistical Analysis ◽

Wear Rate ◽

Taguchi Method ◽

Feed Rate ◽

High Speed ◽

Flank Wear ◽

Cutting Speed ◽

Depth Of Cut ◽

High Speed Machining ◽

Aisi D2

High speed machining has many advantages in reducing time to the market by increasing the material removal rate. However, final surface quality is one of the main challenges for manufacturers in high speed machining due to the increasing of flank wear rate. In high speed machining, the cutting zone is under high pressure associated with high temperature that lead to increasing of the flank wear rate in which affect the final quality of the machined surface. Therefore, one of the main concerns to the manufacturer is to predict the flank wear to estimate and predict the surface roughness as one of the main outputs of the machining processes. The aim of this study is to determine experimentally the optimum cutting parameters: depth of cut, cutting speed (Vc) and feed rate (f) that maintaining low flank wear (Vb). Taguchi method has been applied in this experiment. The Taguchi method has been universally used in engineering analysis. JMP statistical analysis software is used to analyse statically the development of flank wear rate during high speed milling of hardened steel AISI D2 to 60 HRD. The experiment was conducted in the following boundaries: cutting speed 200-400 m/min, feed rate of 0.01-0.05 mm/tooth and depth of cut of 0.1-0.2 mm. Analysis of variance ANOVA was conducted as one of important tool for statistical analysis. The result showed that cutting speed is the most influential input factors with 70.04% contribution on flank wear.

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Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

Materials ◽

10.3390/ma12223749 ◽

2019 ◽

Vol 12 (22) ◽

pp. 3749 ◽

Cited By ~ 6

Author(s):

Adel T. Abbas ◽

Neeraj Sharma ◽

Saqib Anwar ◽

Faraz H. Hashmi ◽

Muhammad Jamil ◽

...

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Titanium Alloys ◽

Material Removal Rate ◽

Material Removal ◽

High Speed ◽

Removal Rate ◽

Depth Of Cut ◽

Optimization Approach ◽

High Speed Machining

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.

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Multi-Response Optimization in High-Speed Machining of Ti-6Al-4V Using TOPSIS-Fuzzy Integrated Approach

Materials ◽

10.3390/ma13051104 ◽

2020 ◽

Vol 13 (5) ◽

pp. 1104 ◽

Cited By ~ 5

Author(s):

Adel T. Abbas ◽

Neeraj Sharma ◽

Saqib Anwar ◽

Monis Luqman ◽

Italo Tomaz ◽

...

Keyword(s):

Titanium Alloys ◽

High Speed ◽

Removal Rate ◽

Cutting Speed ◽

Optimal Solution ◽

Cutting Parameters ◽

Integrated Approach ◽

High Heat ◽

Depth Of Cut ◽

Cutting Processes

Titanium alloys are widely used in various applications including biomedicine, aerospace, marine, energy, and chemical industries because of their superior characteristics such as high hot strength and hardness, low density, and superior fracture toughness and corrosion resistance. However, there are different challenges when machining titanium alloys because of the high heat generated during cutting processes which adversely affects the product quality and process performance in general. Thus, optimization of the machining conditions while machining such alloys is necessary. In this work, an experimental investigation into the influence of different cutting parameters (i.e., depth of cut, cutting length, feed rate, and cutting speed) on surface roughness (Rz), flank wear (VB), power consumption as well as the material removal rate (MRR) during high-speed turning of Ti-6Al-4V alloy is presented and discussed. In addition, a backpropagation neural network (BPNN) along with the technique for order of preference by similarity to ideal solution (TOPSIS)-fuzzy integrated approach was employed to model and optimize the overall cutting performance. It should be stated that the predicted values for all machining outputs demonstrated excellent agreement with the experimental values at the selected optimal solution. In addition, the selected optimal solution did not provide the best performance for each measured output, but it achieved a balance among all studied responses.

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Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

Materials ◽

10.3390/ma13245677 ◽

2020 ◽

Vol 13 (24) ◽

pp. 5677

Author(s):

Elshaimaa Abdelnasser ◽

Azza Barakat ◽

Samar Elsanabary ◽

Ahmed Nassef ◽

Ahmed Elkaseer

Keyword(s):

Surface Roughness ◽

Feed Rate ◽

High Speed ◽

Hard Turning ◽

Cutting Temperature ◽

Cutting Speed ◽

Polycrystalline Diamond ◽

Depth Of Cut ◽

High Speed Machining ◽

Conventional Machining

This article presents the results of an experimental investigation into the machinability of Ti6Al4V alloy during hard turning, including both conventional and high-speed machining, using polycrystalline diamond (PCD) inserts. A central composite design of experiment procedure was followed to examine the effects of variable process parameters; feed rate, cutting speed and depth of cut (each at five levels) and their interaction effects on surface roughness and cutting temperature as process responses. The results revealed that cutting temperature increased with increasing cutting speed and decreasing feed rate in both conventional and high-speed machining. It was found that high-speed machining showed an average increase in cutting temperature of 65% compared with conventional machining. Nevertheless, high-speed machining showed better performance in terms of lower surface roughness despite using higher feed rates compared to conventional machining. High-speed machining of Ti6Al4V showed an improvement in surface roughness of 11% compared with conventional machining, with a 207% increase in metal removal rate (MRR) which offered the opportunity to increase productivity. Finally, an inverse relationship was verified between generated cutting temperature and surface roughness. This was attributed mainly to the high cutting temperature generated, softening, and decreasing strength of the material in the vicinity of the cutting zone which in turn enabled smoother machining and reduced surface roughness.

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Study of High-Speed Machining Parameters on Nickel-Based Alloy GH2132

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.189-193.3142 ◽

2011 ◽

Vol 189-193 ◽

pp. 3142-3147 ◽

Cited By ~ 2

Author(s):

Dong Qiang Gao ◽

Zhong Yan Li ◽

Zhi Yun Mao

Keyword(s):

Tool Wear ◽

Cutting Force ◽

High Speed ◽

Cutting Speed ◽

Main Tool ◽

Cutting Parameters ◽

Depth Of Cut ◽

Machining Parameters ◽

High Speed Machining ◽

Nickel Based Alloy

A model of stress and temperature field is established on nickel-based alloy cutting by finite element modeling and dynamic numerical simulating, and then combining high-speed machining test and orthogonality analysis method, the influence law of cutting parameters on the cutting force and tool wear has been researched, and the tool life and cutting force prediction model based on cutting parameters has been obtained. Finally, by genetic algorithm method cutting parameters are selected reasonably and optimized. The result shows that the bonding wear is main tool wear, and the influence of cutting speed on cutting force is smaller than feed per tooth and axial depth of cut.

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Prediction of Surface Roughness in High Speed Machining of Inconel 718

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.1193 ◽

2011 ◽

Vol 264-265 ◽

pp. 1193-1198

Author(s):

Mokhtar Suhaily ◽

A.K.M. Nurul Amin ◽

Anayet Ullah Patwari

Keyword(s):

Surface Roughness ◽

Surface Finish ◽

Inconel 718 ◽

High Speed ◽

End Milling ◽

Cutting Speed ◽

Cutting Parameters ◽

Machining Process ◽

Depth Of Cut ◽

High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

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Surface Roughness Analysis in High Speed-Dry Turning of a Tool Steel

ASME 2010 10th Biennial Conference on Engineering Systems Design and Analysis, Volume 1 ◽

10.1115/esda2010-24811 ◽

2010 ◽

Cited By ~ 6

Author(s):

N. M. Vaxevanidis ◽

N. I. Galanis ◽

G. P. Petropoulos ◽

N. Karalis ◽

P. Vasilakakos ◽

...

Keyword(s):

Surface Roughness ◽

Tool Steel ◽

High Speed ◽

Surface Defects ◽

Cutting Speed ◽

Depth Of Cut ◽

Machining Parameters ◽

High Speed Machining ◽

Dry Turning ◽

Roughness Analysis

High-speed machining is widely applied for the processing of lightweight materials and also structural and tool steels. These materials are intensively used in the aerospace and the automotive industries. The advantages of high-speed machining lie not only in the speed of machining (lower costs and higher productivity) but also in attaining higher surface quality (prescribed surface roughness without surface defects). Based on this concept, in the present paper the high speed-dry turning of AISI O, (manganese-chromium-tungsten / W.-Nr. 1.2510) tool-steel specimens is reported. The influence of the main machining parameters i.e., cutting speed, feed rate and depth of cut on the resulted center-line average surface roughness (Ra) is examined. Types of wear phenomena occurred during the course of the present experimental study as well as tool wear patterns were also monitored.

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The Use of the Taguchi-Grey Based to Optimize High Speed End Milling with Multiple Performance Characteristics

Materials Science Forum ◽

10.4028/www.scientific.net/msf.505-507.835 ◽

2006 ◽

Vol 505-507 ◽

pp. 835-840 ◽

Cited By ~ 1

Author(s):

Shen Jenn Hwang ◽

Yunn Lin Hwang ◽

B.Y. Lee

Keyword(s):

High Speed ◽

End Milling ◽

Removal Rate ◽

Cutting Speed ◽

Performance Characteristics ◽

Depth Of Cut ◽

Machining Parameters ◽

Machining Performance ◽

Grey Relational Grade ◽

Grey Relational

This paper presents a new approach for the optimization of the high speed machining (HSM) process with multiple performance characteristics based on the orthogonal array with the grey relational analysis has been studied. Optimal machining parameters can then be determined by the grey relational grade as the performance index. In this study, the machining parameters such as cutting speed, feed rate and axial depth of cut are optimized under the multiple performance characteristics including, tool life, surface roughness, and material removal rate(MMR). As shown experimental results, machining performance in the HSM process can be improved effectively through this approach.

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