scholarly journals Towards Analysis and Optimization during Machining Hardened Steel AISI 4140 with Self-Propelled Rotary Tools

2021 ◽  
Author(s):  
Waleed Ahmed ◽  
Hussien Hegab ◽  
Atef Mohany ◽  
Hossam Kishawy
Keyword(s):  
Tool Wear ◽  
Inclination Angle ◽  
Removal Rate ◽  
Weight Ratio ◽  
High Strength ◽  
Hardened Steel ◽  
Machining Process ◽  
Nsga Ii ◽  
Aisi 4140 ◽  
Steel Aisi

Abstract It is necessary to improve the machinability of difficult-to-cut materials such as hardened steel, nickel-based alloys, and titanium alloys as these materials offer superior properties such as chemical stability, corrosion resistance, and high strength to weight ratio, making them indispensable for many applications. Machining with self-propelled rotary tools (SPRT) is considered as one of the promising techniques used to provide proper tool life even under dry conditions. In this work, an attempt has been performed to analyze, model, and optimize the machining process of AISI 4140 hardened steel using self-propelled rotary tools. Experimental analysis has been offered to (a) compare the fixed and rotary tools performance, and (b) study the effect of the inclination angle on the surface quality and tool wear. Moreover, the current study implemented some artificial intelligence-based approaches (i.e., genetic programming and NSGA-II) to model and optimize the machining process of AISI 4140 hardened steel with self-propelled rotary tools. The feed rate, cutting velocity, and inclination angle are selected to be the design variables, while the tool wear, surface roughness, and material removal rate (MRR) are the studied outputs. Moreover, different weights have been assigned for the three studied outputs to offer different optimized solutions based on the designer interest (equal-weighted, finishing, and productivity scenarios). It should be stated that the findings of the current work offer valuable recommendations to select the optimized cutting conditions when machining hardened steel AISI 4140.

scholarly journals Analysis and Optimization of Machining Hardened Steel AISI 4140 with Self-Propelled Rotary Tools

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6106
Author(s):  
Waleed Ahmed ◽  
Hussien Hegab ◽  
Atef Mohany ◽  
Hossam Kishawy
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Inclination Angle ◽  
Feed Rate ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Hardened Steel ◽  
Machining Process ◽  
Aisi 4140 ◽  
Steel Aisi

It is necessary to improve the machinability of difficult-to-cut materials such as hardened steel, nickel-based alloys, and titanium alloys as these materials offer superior properties such as chemical stability, corrosion resistance, and high strength to weight ratio, making them indispensable for many applications. Machining with self-propelled rotary tools (SPRT) is considered one of the promising techniques used to provide proper tool life even under dry conditions. In this work, an attempt has been performed to analyze, model, and optimize the machining process of AISI 4140 hardened steel using self-propelled rotary tools. Experimental analysis has been offered to (a) compare the fixed and rotary tools performance and (b) study the effect of the inclination angle on the surface quality and tool wear. Moreover, the current study implemented some artificial intelligence-based approaches (i.e., genetic programming and NSGA-II) to model and optimize the machining process of AISI 4140 hardened steel with self-propelled rotary tools. The feed rate, cutting velocity, and inclination angle were the selected design variables, while the tool wear, surface roughness, and material removal rate (MRR) were the studied outputs. The optimal surface roughness was obtained at a cutting speed of 240 m/min, an inclination angle of 20°, and a feed rate of 0.1 mm/rev. In addition, the minimum flank tool wear was observed at a cutting speed of 70 m/min, an inclination angle of 10°, and a feed rate of 0.15 mm/rev. Moreover, different weights have been assigned for the three studied outputs to offer different optimized solutions based on the designer’s interest (equal-weighted, finishing, and productivity scenarios). It should be stated that the findings of the current work offer valuable recommendations to select the optimized cutting conditions when machining hardened steel AISI 4140 within the selected ranges.

Electric Discharge Machining of Cryo-Treated BeCu Alloys

2015 ◽  
Vol 787 ◽  
pp. 386-390
Author(s):  
Sandeep Chinke ◽  
Vijaykumar S. Jatti ◽  
T.P. Singh
Keyword(s):  
Tool Wear ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Cryogenic Treatment ◽  
High Strength ◽  
Machining Process ◽  
Tool Electrode ◽  
Severe Problem ◽  
Magnetic Strength ◽  
Conventional Machining

Beryllium copper possesses high strength which produces severe problem of surface integrity and tool wear during machining by conventional machining process. Electrical discharge machining is a practically viable option to solve this problem. The present study investigates the effect of cryogenic treatment of work part along with gap current and external magnetic field on material removal rate (MRR) and tool wear rate (TWR). Blind 3 mm square holes were produced using electrolytic copper tool electrode to machine cryo-treated BeCu and untreated BeCu. Gap current is varied from 8 A to 16 A in a step of 2 amperes and magnetic strength is varied from 0 to 0.496 T in a step of 0.124 T. Based on the experimental results it was found that MRR increases with increase in gap current for both untreated BeCu and treated work part. Plotted graphs of cryo-treated work part showed high values of MRR in comparison to untreated work part. TWR increases for both treated and untreated BeCu work part with increase in gap current. But the TWR was less for cryo-treated work part in comparison to untreated work part. MRR and TWR increases for both treated and untreated BeCu work part with increasing magnetic strength. Again the MRR was found higher with lower TWR for treated workpiece with regard to magnetic strength. Thus it can be concluded that cryogenic-treatment with magnetic strength improves EDM machining efficiency.

Study on the cutting performance in machining assembled hardened steel workpiece with torus cutter

2019 ◽  
Vol 234 (4) ◽  
pp. 701-709
Author(s):  
Tao Chen ◽  
Weijie Gao ◽  
Guangyue Wang ◽  
Xianli Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Quality ◽  
Wear Mechanism ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Machining Process ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Two Sides

Torus cutters are increasingly used in machining high-hardness materials because of high processing efficiency. However, due to the large hardness variation in assembled hardened steel workpiece, the tool wear occurs easily in machining process. This severely affects the machined surface quality. Here, we conduct a research on the tool wear and the machined surface quality in milling assembled hardened steel mold with a torus cutter. The experimental results show the abrasive wear mechanism dominates the initial tool wear stage of the torus cutter. As the tool wear intensifies, the adhesive wear gradually occurs due to the effect of alternating stress and impact load. Thus, the mixing effect of the abrasive and adhesive wears further accelerates tool wear, resulting in occurrence of obvious crater wear band on the rake face and coating tearing area on the flank face. Finally, the cutter is damaged by the fatigue wear mechanism, reducing seriously the cutting performance. With increase of flank wear, moreover, there are increasingly obvious differences in both the surface morphology and the cutting force at the two sides of the joint seam of the assembled hardened steel parts, including larger height difference at the two sides of the joint seam and sudden change of cutting force, as a result, leading to decreasing cutting stability and deteriorating seriously machined surface quality.

scholarly journals An experimental study on the effect of tool geometry on tool wear and surface roughness in hard turning

2020 ◽  
Vol 12 (9) ◽  
pp. 168781402095988
Author(s):  
Pham Minh Duc ◽  
Le Hieu Giang ◽  
Mai Duc Dai ◽  
Do Tien Sy
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Inclination Angle ◽  
Hard Turning ◽  
Rake Angle ◽  
Machining Process ◽  
Tool Geometry ◽  
Standard Tool ◽  
Inclination Angles ◽  
Mixed Ceramic

The main purpose of this study is to investigate the influence of tool geometry (cutting edge angle, rake angle, and inclination angle) and to optimize tool wear and surface roughness in hard turning of AISI 1055 (52HRC) hardened steel by using TiN coated mixed ceramic inserts. The results show that the inclination angle is the major factor affecting the tool wear and the surface roughness in hard turning. With the increase in negative rake and inclination angles, the tool wear decreases, and the surface roughness increases. However, the surface roughness will decrease when the inclination angle increases to overpass a certain limit. This is a new and significant point in the research of the hard turning process. From this result, the large negative inclination angle (λ = −10°) should be applied to reduce the surface roughness and the tool wear simultaneously. With the optimal cutting tool angles in the research, the hard machining process is improved remarkably with decreases of surface roughness and tool wear 8.3% and 41.3%, respectively in comparison with the standard tool angles. And the proposed tool-post design approach brings an effective method to change the tool insert angles using standard tool-holders to improve hard or other difficult-to-cut materials turning quality.

Intelligent Modeling and Optimization of Material Removal Rate in Electric Discharge Diamond Grinding

2012 ◽  
Author(s):  
Pankaj Kumar Shrivastava ◽  
Avanish Kumar Dubey
Keyword(s):  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Iron Carbide ◽  
Hybrid Approach ◽  
Weight Ratio ◽  
Manufacturing Industries ◽  
Machining Process ◽  
Diamond Grinding

Metal matrix composites (MMCs) have wide applications in modern manufacturing industries due to their specific and improved technological characteristics such as high strength to weight ratio, high hardness, high thermal, corrosion and wear resistances. Such characteristics are highly demanded in automobile, aircraft and space research organizations. Shaping of MMCs has been a big challenge for manufacturing industries due to their superior mechanical properties and the peculiar microstructure composed of different phases in MMCs poses machining challenges. Unconventional machining methods have become an alternative to give desired shapes with intricate profiles and stringent design requirements. The aim of present research is to investigate the machining performance of copper-iron-carbide MMC using hybrid machining process, electric discharge diamond grinding (EDDG). A hybrid approach of neural network and genetic algorithm has been used to develop the intelligent model for material removal rate (MRR) and subsequent optimization with the experimental data obtained by scientifically designed experimentation.

Multi-Objective Optimization on Drilling of Titanium Alloy (Ti6Al4V)

2013 ◽  
Vol 763 ◽  
pp. 29-49 ◽  
Author(s):  
A. Prabukarthi ◽  
V. Krishnaraj ◽  
M. Senthil Kumar
Keyword(s):  
Titanium Alloy ◽  
Thrust Force ◽  
Optimization Technique ◽  
Weight Ratio ◽  
High Strength ◽  
Hole Diameter ◽  
Machining Process ◽  
Multi Objective ◽  
Titanium Alloy Ti6al4v ◽  
Exit Burr

Titanium alloys present superior properties like resistance to corrosion, high strength to weight ratio etc, but possess poor machinability. Titanium alloy Ti-6Al-4V is the most commonly used titanium alloy in aerospace and medical device industries. Titanium and its alloys are notorious for their poor thermal properties and are classified as difficult-to-machine materials. Drilling is an important machining process since it is involved in nearly all titanium applications. It is desirable to develop optimized drilling processes for Ti and improve the hole characteristics such as hole diameter, circularity and exit burr of currently available processes. Due to the low machinability of the alloys under study, selecting the machining conditions and parameters is crucial. The range of spindle speed and feed rate, which provide a satisfactory tool life, is very limited. The hole quality (hole diameter and circularity), thrust force, torque and exit burr were evaluated at various spindle speeds, feed rates combinations. The optimized parameter is chosen using the multi-objective weighted sum optimization technique.

Turning of Austempered Ductile Iron with ceramic tools

2020 ◽  
pp. 095440542095715 ◽  
Author(s):  
A Fernández-Valdivielso ◽  
LN López de Lacalle ◽  
P Fernández-Lucio ◽  
H González
Keyword(s):  
Heat Treatment ◽  
Tool Wear ◽  
Ductile Iron ◽  
High Strength ◽  
Cutting Parameters ◽  
Precise Determination ◽  
Machining Process ◽  
Austempered Ductile Iron ◽  
Machining Time ◽  
Ceramic Tools

Austempered ductile iron castings (ADI) are characterized by the high strength and resistance to fatigue, impact, and wear. ADI mechanical properties are obtained by performing a heat treatment on ductile iron casting. Thus, the so-called ausferrite microstructure is achieved. However, heat treatment significantly affects ductile casting machinability. A precise determination of ADI microstructure, on the one hand, and to choose correct machining process parameters and tool wear control on the other, are essential to optimize cutting processes and for the introduction of ceramic inserts. Ceramics are an alternative to carbide tools. In this paper, ceramic tools for the dry turning of ADI castings are studied. Thus, different technical ceramics were analyzed, identifying the dominant wear mechanism and evolution. Tool wear rate magnitude was determined indirectly by the variation of cutting force along machining time. Finally, different tests helped to study ceramics wear sensitivity with respect to cutting parameters. Mixed ceramics of Al2O3 with TiC showed the best performance, followed by SiAlON ones.

Abrasive Assisted Electrochemical Machining of Al-B4C Nanocomposite

2015 ◽  
Vol 787 ◽  
pp. 523-527 ◽  
Author(s):  
K. Rajkumar ◽  
L. Poovazhgan ◽  
P. Saravanamuthukumar ◽  
S. Javed Syed Ibrahim ◽  
S. Santosh
Keyword(s):  
Particle Size ◽  
Boron Carbide ◽  
Process Parameters ◽  
Positive Impact ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Weight Ratio ◽  
High Strength ◽  
High Wear Resistance ◽  
Particle Size Reduction

Aluminium reinforced with SiC, Al2O3 and B4C etc. possesses an attractive combination of properties such as high wear resistance, high strength to weight ratio and high specific stiffness. Among the various reinforced materials used for aluminium, B4C has outperformed all others in terms of hardening effect. Particle size reduction of B4C is found to have positive impact on the material hardness. In the view of physical properties, B4C has less density than that of SiC and Al2O3, which makes it an attractive reinforcement for aluminium and its alloys for light weight applications. In this work, Al nano B4C composite prepared by ultrasonic cavitation method was machined by Abrasive assisted electrochemical machining using cylindrical copper tool electrodes with SiC abrasive medium. In this paper, attempts have been made to model and optimize process parameters in Abrasive assisted Electro-Chemical Machining of Aluminium-Boron carbide nano composite. Optimization of process parameters is based on the statistical techniques using Response Surface Methodology with four independent input parameters such as voltage, current, abrasive concentration and feed rate were used to assess the process performance in terms of material removal rate and surface finish. The obtained results were compared with abrasive assisted electro chemical machining of Aluminium-Boron carbide micro composite and the effect of particle size on the process parameters was analyzed.

Investigation of Trochoidal Milling in Nickel-Based Superalloy Inconel 738 and Comparison With End Milling

2014 ◽  
Author(s):  
Abram Pleta ◽  
Durul Ulutan ◽  
Laine Mears
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
End Milling ◽  
Removal Rate ◽  
Extreme Environments ◽  
High Strength ◽  
Machining Time ◽  
Trochoidal Milling ◽  
Nickel Based Superalloy

Nickel-based superalloys are designed for use in extreme environments and are getting progressively better for these environments, therefore much harder to machine. They play a crucial role in elevated temperature applications where high strength, high resistance to corrosion and creep resistance are required. Machinability suffers as a result of these properties and harsh machining conditions occur, resulting in high cutting forces and tool wear. To combat the difficulties in the machining of nickel-based superalloys, such as poor thermal diffusivity and high levels of abrasive wear, trochoidal milling was introduced as an alternative method of milling. This method of milling combines linear motion with uniform circular motion, reducing chip load in exchange for increased machining time. Industry is averse to its widespread adoption due to increasing cycle times when compared to conventional milling methods, however it has been shown that overall productivity can be improved due to less tool wear with a more predictable behavior. This work characterizes the effects of trochoidal milling and provides a comparison of trochoidal milling with a traditional milling technique, end milling, for the machining of Inconel 738. In order to compare the trochoidal and conventional machining approaches directly, metrics of productivity normalized to tool wear are introduced. The normalized metrics introduced in this study aim to provide a more representative comparison of productivity and efficiency characteristics: volumetric material removal per unit tool wear (MR/VB) and the material removal rate per unit tool wear (MRR/VB). It was found that significantly higher volumetric material removal is possible using trochoidal milling, and fewer tools are needed; material removal rates that competitive with end milling can be achieved. When the amount of time spent on tool change for the same volume of material removal is considered, material removal rate of trochoidal milling can even be higher than end milling, indicating that better productivity and efficiency of the process is possible at reduced tooling costs.

scholarly journals PENGARUH GAYA POTONG PEMBUBUTAN TERHADAP KEAUSAN PAHAT KARBIDA COATED PADA BENDA KERJA BAJA AISI 4340

POROS ◽  
2018 ◽  
Vol 16 (1) ◽  
Author(s):  
Rosehan Rosehan Rosehan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Alloy Steel ◽  
Tool Life ◽  
Cutting Tools ◽  
Machining Process ◽  
Maximum Value ◽  
Trial Analysis ◽  
Steel Aisi ◽  
Aisi 4340

Cutting force and tool life is the important data in planning a machining process. The research is in order to describe about the influence of the cutting force to the tool wear on carbide coated cutting tools used the turning process of an alloy steel of AISI 4340. The research was conducted by observing the growth of tool wear on minutes 4.5, 9, 13.5, 18, 22.5 with the maximum value VB 0.3 mm, at the same time, the condition of other cutting such as the motion while the cutting, the depth and speed of the cutting movement was constant. The purpose of this experiment is to examine scientifically the influence cutting force to the growth of tool wear on carbide coated while the cutting process of alloy steel AISI 4340. The graphical method was used for the trial analysis, to see the cutting force comparison with the decrease of tool life of the carbide coated, and the correlation of the cutting movement with the cutting force. The mechanism decrease showed the adhesion decrease.

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