scholarly journals Optimization of Cutting Parameters to Minimize Tooling Cost in High Speed Turning of SS304 using Coated Carbide Tool using Genetic Algorithm Method

2016 ◽  
Vol 1 (1) ◽  
pp. 11-15
Author(s):  
Muataz Hazza ◽  
Nur Amirah Najwa
Keyword(s):  
Genetic Algorithm ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Carbide Tool ◽  
High Speed Turning ◽  
Coated Carbide Tool ◽  
Optimization Of Cutting Parameters ◽  
Coated Carbide

High speed turning (HST) is an approach that can be used to increase the material removal rate (MRR) by higher cutting speed. Increasing MRR will lead to shortening time to market. In contrast, increasing the cutting speed will lead to increasing the flank wear rate and then the tooling cost.  However, the main factor that will justify the best level of cutting speed is the tooling cost which merges all in one understandable measurable factor for manufacturer. The aim of this paper is to determine experimentally the optimum cutting levels that minimize the tooling cost in machining AISI 304 as a work piece machined by a coated carbide tool using one of the non-conventional methods: Genetic Algorithm (GA). The experiments were designed using Box Behnken Design (BBD) as part of Response Surface Methodology (RSM) with three input factors: cutting speed, feeding speed and depth of cut.

A Study of the Sensitivity of Parameters Affecting Coated Tool Life in High Speed Milling Superalloy GH4169

2013 ◽  
Vol 651 ◽  
pp. 436-441
Author(s):  
Wei Wei Liu ◽  
Xu Sheng Wan ◽  
Yuan Yu ◽  
Feng Li ◽  
Hao Chen
Keyword(s):  
High Temperature ◽  
Tool Life ◽  
High Speed ◽  
Depth Of Cut ◽  
Linear Regression Method ◽  
Carbide Tool ◽  
High Temperature Alloy ◽  
High Speed Milling ◽  
Coated Carbide Tool ◽  
Coated Carbide

Through the orthogonal test of the TiALN coated carbide tool high-speed milling of high-temperature alloy GH4169, the empirical formula of the tool life are acquired by using multiple linear regression method. On the basis of this formula, studying the absolute sensitivity and relative sensitivity of TiALN coated carbide tool life for milling speed, depth of cut and feed; The results showed that in the process of high-speed milling of high-temperature alloy GH4169, tool life decreased with the increase of milling speed, feed and depth of cut; tool life is most sensitive to the change of milling speed; change of feed take second place and milling depth is the least sensitive.

Using the Desirability Function as an Effective Tool in Target Costing Model

2015 ◽  
Vol 1115 ◽  
pp. 126-129
Author(s):  
Muataz Hazza F. Al Hazza ◽  
Mohamed Konneh ◽  
Mohammad Iqbal ◽  
Assem Hatem Taha ◽  
Muhammad H. Hasan
Keyword(s):  
High Speed ◽  
Desirability Function ◽  
Cutting Speed ◽  
Machining Process ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Target Costing ◽  
Economic Study ◽  
High Speed Turning ◽  
Coated Carbide

High speed turning (HST) is an advanced machining process that uses higher cutting speeds than those used in conventional machining. HST enables manufacturers to shorten machining times. Therefore, this approach should be followed and justified by economic study. One of the most effective tools for economic study is by developing a target-cost model to control the machining cost. The aim of this research is to develop a target costing model for high speed turning. To achieve the aim of this research, a set of experimental data was obtained in the following cutting levels: cutting speed (500-700 m/min), feed rate (1000-2000 mm/min), and depth of cut of (0.1-0.3) mm. The materials used in this research were AISI 304 stainless steel as a work piece material and coated carbide as a cutting tool. The output data was used to develop a target costing model. The desirability function has been used to optimize the model.

Reliability and economic analysis in sustainable machining of Monel 400 alloy

2021 ◽  
pp. 095440622098681
Author(s):  
Ashwani Tayal ◽  
Nirmal Singh Kalsi ◽  
Munish Kumar Gupta ◽  
A Garcia-Collado ◽  
Murat Sarikaya
Keyword(s):  
Surface Roughness ◽  
Economic Analysis ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Turning ◽  
Sustainable Machining ◽  
Coated Carbide Tool ◽  
Prime Concern ◽  
Coated Carbide

Engineering field nurtures a variety of superalloys and its wide applications due to the inherent properties of such material. The prime concern of working engineers is to explore reliability, quality, economy, and machinability analysis of these superalloys. In this work, sustainable machining of Monel 400superalloy using PVD multilayer coated carbide tool under dry turning was studied. Surface roughness (Ra, Rz, and Rq), power (P) and cutting force (Fc) were addressed as responses. The subsequent effect of cutting speed, feed and depth of cut on the responses was explored through response surface methodology (RSM), statistical analysis of variance (ANOVA) and multiple regression analysis. Details of tool wear was observed via scanning electron microscope (SEM) to know the cutting behavior at interface. Further, the reliability and economic analysis were performed to substantiate the feasibility of cutting insert. The investigation reveals that surface roughness was affected by feed and cutting speed. The increase in cutting speed uncovers lower cutting forces with improved surface finish during dry turning which further reduces the power requirement. The economic analysis shows unit production time and unit production cost based on a single insert PVD coated carbide tool under optimum value condition. The reliability analysis exposes the meantime to repair (MTTR) (5 min), mean time between failure (MTBF) (28 min), availability (84.8%), failure rate (0.03), and reliability (80.5%) for the production system.

Wear Mechanism of High-Speed Turning Ti-6Al-4V with TiAlN and AlTiN Coated Tools in Dry and MQL Conditions

2012 ◽  
Vol 497 ◽  
pp. 30-34 ◽  
Author(s):  
Jin Yang Xu ◽  
Zhi Qiang Liu ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
Carbide Tool ◽  
High Speed Turning ◽  
Coated Carbide Tool ◽  
Coated Tool ◽  
Coated Carbide ◽  
Oxidation Wear

The TiAlN and AlTiN coated carbide cutting tools were adopted for high-speed turning of α+β phase titanium alloy Ti-6Al-4V. Both the wear pattern and wear mechanism were investigated in this research. Results show that: MQL condition can greatly prolong the tool life of AlTiN coated carbide tool but has minor influence on improving the tool life of TiAlN carbide tool. AlTiN coated carbide tool was found to be qualified to obtain better cutting performance and longer tool life and is more suitable for processing titanium alloy TC4 compared with TiAlN coated tool under the same cutting parameters. In dry cutting condition, both adhesive and oxidation wear were observed to be the main wear types in these two coated carbide tools. However, in MQL condition, TiAlN coated tool may only suffer adhesive wear while the AlTiN coated carbide tool suffer adhesive, diffusion and oxidation wear.

Experimental Investigation on Cutting Forces and Temperature in High Speed Turning of Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17) Alloys

2012 ◽  
Vol 472-475 ◽  
pp. 1054-1058
Author(s):  
Bao Lin Wang ◽  
Xing Ai ◽  
Zhan Qiang Liu ◽  
Ji Gang Liu
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Type Alloy ◽  
High Speed Turning ◽  
Orthogonal Turning ◽  
Coated Carbide ◽  
Cutting Speeds

In this study, orthogonal turning experiments are performed to analyze the machinability of Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), a β-rich, α+β type alloy. PVD TiAlN coated carbide tool inserts are applied, because they are used widely for machining this material. The cutting forces and cutting temperatures are examined under different cutting conditions, which the cutting speeds are varied from 44m/min to 123m/min, the feed rates are 0.06mm/r, 0.08mm/r, 0.10mm/r and 0.12mm/r,respectively.There are some different varying trends of both the cutting force and the thrust force with the change of cutting speed. The cutting temperatures are found to increase with cutting speeds as well as feed rates.

Tool Life Prediction and Cutting Parameter Optimization for Coated Carbide in Ti6Al4V Turning

2012 ◽  
Vol 426 ◽  
pp. 186-189
Author(s):  
X.Q Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
X.L. Fu ◽  
Y. Z. Pan
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Contour Analysis ◽  
Cutting Efficiency ◽  
Coated Carbide Tool ◽  
Cutting Parameter Optimization ◽  
Coated Carbide

Ti6Al4V is a difficult to machine alloy with low cutting efficiency and server tool wear. A series of orthogonal turning tests with coated carbide in higher speed scale was carried out on a CA6140 lathe. The experiential functions of tool life based on orthogonal experiment were developed. The tool wear morphologies were examined by scanning electron microscope (SEM) and energy disperse spectroscopy (EDS), adhesion, diffusion and micro-chipping were the major wear mechanisms of coated carbide tool. Finally, the cutting parameters of coated carbide tool in Ti6Al4V dry turning were optimized based on tool life-efficiency contour analysis, in same cutting efficiency, the lower cutting speed and larger depth of cut are the better selection in Ti6Al4V turning for coated carbide tool.

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

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