RSM Based Investigations on the Effects of Cutting Parameters on Surface Integrity during Cryogenic Hard Turning of AISI 52100

2015 ◽  
Vol 15 (3) ◽  
pp. 309-318 ◽  
Author(s):  
Suha K. Shihab ◽  
Zahid A. Khan ◽  
Arshad Noor Siddiquee
Keyword(s):  
Surface Integrity ◽  
Feed Rate ◽  
Hard Turning ◽  
Desirability Function ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Aisi 52100 ◽  
Model Equations

AbstractEffect of cryogenic hard turning parameters (cutting speed, feed rate, and depth of cut) on surface roughness (Ra) and micro-hardness (µH) that constitute surface integrity (SI) of the machined surface of alloy steel AISI 52100 is investigated. Multilayer hard surface coated (TiN/TiCN/Al2O3/TiN) insert on CNC lathe is used for turning under different cutting parameters settings. RSM based Central composite design (CCD) of experiment is used to collect data for Ra and µH. Validity of assumptions related to the collected data is checked through several diagnostic tests. The analysis of variance (ANOVA) is used to determine main and interaction effects. Relationship between the variables is established using quadratic regression model. Both Ra and µH are influenced principally by the cutting speed and the feed rate. Model equations are found to predict accurate values of Ra and µH. Finally, desirability function approach for multiple response optimization is used to produce optimum SI.

Investigations on the Effect of CNC Dry Hard Turning Process Parameters on Surface Integrity: A Multi-performance Characteristics Optimization

2014 ◽  
Vol 14 (1) ◽  
pp. 23-30 ◽  
Author(s):  
Suha K. Shihab ◽  
Zahid A. Khan ◽  
Aas Mohammad ◽  
Arshad Noor Siddiquee
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Influential Factor ◽  
Depth Of Cut ◽  
Micro Hardness ◽  
Dry Cutting

AbstractThe cutting parameters such as the cutting speed, the feed rate, the depth of cut, etc. are expected to affect the two constituents of surface integrity (SI), i.e., surface roughness and micro-hardness. An attempt has been made in this paper to investigate the effect of the CNC hard turning parameters on the surface roughness average (Ra) and the micro-hardness (μh) of AISI 52100 hard steel under dry cutting conditions. Nine experimental runs based on an orthogonal array of the Taguchi method were performed and grey relational analysis method was subsequently applied to determine an optimal cutting parameter setting. The feed rate was found to be the most influential factor for both the Ra and the μh. Further, the results of the analysis of variance (ANOVA) revealed that the cutting speed is the most significant controlled factor for affecting the SI in the turning operation according to the weighted sum grade of the surface roughness average and micro-hardness.

Hard Turning of Hot Work Steel X38CRMOV5-3: Evaluation of Surface Roughness and Current Values Using Cutting Parameters

2020 ◽  
Author(s):  
Ali Kemal Cakir
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Motor Current ◽  
Design Factors

This study evaluates the surface roughness and current values using cutting parameters in the turning of AISI H11 being hot work tool steel under dry machining conditions. The selected design factors are the depth of cut, feed rate, cutting speed. A design of experiments was used to carry out this research. The obtained results were analyzed to determine the effects of input parameters on the resultant surface roughness, current using the analysis of variance (ANOVA) and the Response Surface Methodology (RSM). The experimental results showed that increasing feed rate increased the surface roughness, and current values. The most effective cutting parameter on all the output parameters was found to be the feed rate on the surface roughness. Also, the motor current values were influenced by the 38,48% depth of cut, 23,98% cutting speed, 25,52% feed rate, respectively.

The Effect of Cutting Parameters on Surface Integrity in Hard Turning

2011 ◽  
Vol 110-116 ◽  
pp. 751-757 ◽  
Author(s):  
Sanjeev Saini ◽  
Inderpreet Singh Ahuja ◽  
Vishal S. Sharma
Keyword(s):  
Surface Quality ◽  
Surface Integrity ◽  
Hard Turning ◽  
Lower Cost ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Part Quality ◽  
The World

Manufacturers around the world constantly strive for lower cost solutions in order to maintain their competitiveness on machined components and manufactured goods. Globally, part quality has been found to be at acceptable levels and it continues to improve, while the pressure for part piece cost is enormous and is constantly being influenced downward by competition and buyer strategies. In machining processes, it is necessary to attain the desired surface quality in order to produce parts providing the required functioning. The surface quality is influenced by various cutting parameters (cutting speed, feed, depth of cut) and sometimes some other parameters. The objective of this paper is to review the effect of cutting parameters on surface integrity (surface roughness and residual stress) in hard turning.

scholarly journals Experimental Study on Surface Integrity of Titanium Alloy Ti6Al4V by Ball End Milling

2018 ◽  
Vol 14 (1) ◽  
pp. 115-121 ◽  
Author(s):  
Pun Krishna Kaway ◽  
Xueping Zhang
Keyword(s):  
Titanium Alloy ◽  
Surface Integrity ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Ball End Milling ◽  
Titanium Alloy Ti6al4v ◽  
Cutting Speeds

Titanium alloy, Ti6Al4V, has been widely used in aerospace, automotive, biomedical, and chemical industries due to its exceptional strength to weight ratio, high temperature performance, and corrosion resistance. However, machinability of Ti6Al4V is poor due to high strength at elevated temperatures, low modulus, and low thermal conductivity. Poor machinability of Ti6Al4V deteriorates the surface integrity of the machined surface. Poor surface integrity causes high machining cost, surface defects, initiate cracks, and premature failure of the machined surface. Thus, it is indispensable to obtain better surface integrity when machining titanium alloy Ti6Al4V. Cutting parameters such as cutting speed, feed rate, and depth of cut have significant effect on the surface integrity when machining titanium alloy Ti6Al4V. Hence, this study investigates surface integrity of Ti6Al4V by ball end milling at different cutting speeds, feed rates, and depth of cuts. Microstructure of subsurface is studied at different cutting speeds, feed rates, and depth of cuts. The results show that the depth of deformation of subsurface increases with increase in the cutting speed, feed rate, and depth of cut. Journal of the Institute of Engineering, 2018, 14(1): 115-121

scholarly journals Analysis of tool vibration and surface roughness with tool wear progression in hard turning: An experimental and statistical approach

2020 ◽  
Vol 14 (1) ◽  
pp. 6461-6472
Author(s):  
Nitin Ambhore ◽  
Dinesh Kamble ◽  
Satish Chinchanikar
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Hard Turning ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Tangential Direction ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Tool Vibrations

The machined surface quality and dimensional accuracy obtained during hard turning is prominently gets affected due to tool wear and cutting tool vibrations. With this view, the results of tool wear progression on surface quality and acceleration amplitude is presented while machining AISI 52100 hard steel. Central Composite Rotatable Design (CCRD) is employed to develop experimental plan. The results reported that vibration signals sensed in a tangential direction (Vz) are most sensitive and found higher than the vibrations in the feed direction (Vx) and depth of cut direction (Vy). The acceleration signals in all three directions are observed to increase with the advancement of tool wear and good surface finish is observed as tool wear progresses up-to 0.136mm. The vibration amplitude is discovered high in the range 3 kHz – 10 kHz within selected cutting parameter range (cutting speed 60-180mm/min, feed 0.1-0.5mm/rev, depth of cut 0.1-0.5mm). The investigation is extended for the development of multiple regression models with regression coefficients value 0.9. These models found statically significant and give dependable estimates between a tool vibrations and cutting parameters.

Achieving Optimal Process Parameters during Hard Turning of AISI 52100 Bearing Steel Using Hybrid GRA-PCA

2019 ◽  
Vol 818 ◽  
pp. 87-91 ◽  
Author(s):  
P. Umamaheswarrao ◽  
D. Ranga Raju ◽  
K.N.S. Suman ◽  
B. Ravi Sankar
Keyword(s):  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 52100 ◽  
Input Parameters

In the present work hard turning of AISI 52100 steel has been performed using Polycrystalline cubic boron nitride (PCBN) tools. The input parameters considered are cutting speed, feed, depth of cut, nose radius and negative rake angle and the measured responses are machining force and workpiece surface temperature. Experiments are planned as per Central Composite Design (CCD) of Response Surface Methodology (RSM). The effect of input parameters and their interactions are discussed with main effects plot. Further, the multi-objective optimization scheme is proposed by adopting Grey Relational Analysis (GRA) coupled with Principle Component Analysis (PCA). Results demonstrated that speed is the most significant factor affecting the responses followed by negative rake angle, feed, depth of cut, and nose radius. The optimum cutting parameters obtained are cutting speed 1000 rpm, feed 0.02 mm/rev, depth of cut 0.5 mm, Nose radius 1 mm and Negative rake angle 5o.

Experimental Research on Surface Residual Stress of Quenched GCr15 Steel in Ultrasonic Aided Turning

2013 ◽  
Vol 797 ◽  
pp. 657-662
Author(s):  
Feng Jiao ◽  
Xiang Liu ◽  
Chong Yang Zhao ◽  
Xiong Zhang
Keyword(s):  
Residual Stress ◽  
Compressive Stress ◽  
Surface Integrity ◽  
Hard Turning ◽  
Cutting Speed ◽  
Residual Compressive Stress ◽  
Depth Of Cut ◽  
Surface Residual Stress ◽  
Machined Surface ◽  
Gcr15 Steel

Surface residual stress has become one of the important indexes measuring surface integrity in hard turning of precision parts. The type of surface residual stress and the influence rules of cutting parameters on surface residual stress in hard turning of GCr15 steel are studied in this paper. Research results show that no matter in common or ultrasonic turning, tangential surface residual compressive stress can be found in machined surface. The effect of cutting speed on the residual compressive stress is the greatest, the effect of feed rate takes the second place and the effect of depth of cut is minimal. The conclusions have provided experimental basis for enhancing the surface integrity of quenched GCr15 steel precision parts.

Effect of Machining Parameters on Surface Integrity in Dry Turning of Inconel 718

2013 ◽  
Vol 634-638 ◽  
pp. 2831-2834
Author(s):  
Xiao Li Zhu ◽  
Jin Fa Zhang ◽  
Wu Jun Chen ◽  
Ji Wen Deng
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Surface Integrity ◽  
Feed Rate ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Diffraction Method ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters

Surface quality including residual stresses and surface roughness due to turning operations in Inconel 718 were studied as a function of cutting speed, feed rate and depth of cut. By means of X-ray radiation diffraction method, the influence of cutting parameters on residual stress was investigated. The results show that dry cutting of Inconel 718 resulted in predominantly tensile residual stresses at the machined surface and the surface roughness increased with the increase of cutting parameters.The effects of the cutting parameters on surface integrity are investigated while employing the range analysis. From these results it was possible to select a combination of cutting speed, feed rate and depth of cut that generate favorable surface characteristics.

scholarly journals Effect of Cutting Parameters on Machinability of Hardened AISI 52100 Bearing Steel

2020 ◽  
Vol 3 (1) ◽  
pp. 474-481
Author(s):  
Mohammad Rafighi
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Manufacturing Cost ◽  
Machining Parameters ◽  
Aisi 52100

In this study, the effects of machining parameters, namely feed rate, cutting speed and depth of cut on the surface roughness was investigated experimentally in hard turning of AISI 52100 bearing steel using cubic boron nitride insert under dry cutting condition. Taguchi method was utilized to reduce the number of trials to 9 for saving the time and manufacturing cost. The significant factor on the surface roughness was determined using analysis of variance. Furthermore, the optimum cutting parameter for reducing the surface roughness was obtained. The findings showed that the feed rate has the highest impact on surface roughness among any other cutting parameters, with 88.32% contribution.

Effect of Cutting Parameters on the Quality of the Machined Surface of Cu-Zn-Al Shape Memory Alloy, SMA

2015 ◽  
Vol 1105 ◽  
pp. 93-98
Author(s):  
Adnan I.O. Zaid ◽  
S.M.A. Al-Qawabah
Keyword(s):  
Shape Memory Alloy ◽  
Shape Memory ◽  
Surface Quality ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Direct Extrusion

Shape memory alloys (SMAs) are now widely used in many industrial and engineering applications e.g. in aircrafts, space vehicles, robotics and actuators. However the available literature reveals that little or no work is published on the machinability of these alloys. In this paper, the effect of the main cutting parameters namely: cutting speed, depth of cut and feed rate on the surface quality of the machined surface of the Cu-Zn-Al shape memory alloy both in the cast and after direct extrusion using a CNC milling is investigated. The cutting speed was varied from 750 to 2000 rpm , the depth of cut was varied from 1 to 4 mm and the feed rate was varied from 100 to 250 mm/min. Furthermore, the general microstructure, the mechanical behavior and hardness of the Cu-Zn-Al shape memory alloy both in the cast and after direct extrusion are determined and discussed. It was found that the best achieved surface quality in this SMA, machined within the different investigated cutting conditions is 0.13 microns at cutting speed of 750 rpm, 1 mm depth of cut and 150 mm/min. feed rate, which is better than the surface quality achieved in other materials at the same cutting conditions.

Sign in / Sign up

Export Citation Format

Share Document