Experimental Investigation and Statistical Evaluation of Optimized Cutting Process Parameters and Cutting Conditions to Minimize Cutting Forces and Shape Deviations in Al6026-T9

Precise, economical and sustainable cutting operations are highly desirable in the advanced manufacturing environment. For this aim, the present study investigated the influence of cutting parameters (i.e., the cutting speed (c), feed rate (f), depth of cut (d) and positive rake angle (p)) and sustainable cutting conditions (dry and minimum quantity lubricant (MQL)) on cutting forces (i.e., feed force (Ff), tangential forces (Ft), radial force (Fr) and resultant cutting forces (Fc) and shape deviations (i.e., circularity and cylindricity) of a 6026-T9 aluminum alloy. The type of lubricant and insert used are virgin olive oil and uncoated tungsten carbide tool. Turning experiments were performed on a TAKISAWA TC-1 CNC lathe machine and cutting forces were measured with the help of a Kistler 9257B dynamometer. Shape deviations were evaluated by means of a Tesa Micro-Hite 3D DCC 474 coordinate measuring machine (CMM). Experimental runs were planned based on Taguchi mixture orthogonal array design L16. Analysis of variance (ANOVA) was performed to study the statistical significance of cutting parameters. Taguchi based signal to noise (S/N) ratios are applied for optimization of single response, while for optimization of multiple responses Taguchi based signal to noise (S/N) ratios coupled with multi-objective optimization on the basis of ratio analysis (MOORA) and criteria importance through inter-criteria correlation (CRITIC) are employed. ANOVA results revealed that feed rate, followed by a depth of cut, are the most influencing and contributing factors for all components of cutting forces (Ff, Ft, Fr, and Fc) and shape deviations (circularity and cylindricity). The optimized cutting parameters obtained for multi responses are c = 600 m/min, f = 0.1 mm/rev, d = 1 mm and p = 25°, while for cutting conditions, MQL is optimal.

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Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

Advances in Computational Intelligence and Robotics - Handbook of Research on Predictive Modeling and Optimization Methods in Science and Engineering ◽

10.4018/978-1-5225-4766-2.ch018 ◽

2018 ◽

pp. 398-417

Author(s):

İsmail Kırbaş ◽

Musa Peker ◽

Gültekin Basmacı ◽

Mustafa Ay

Keyword(s):

Feed Rate ◽

Cutting Forces ◽

Cutting Speed ◽

Cutting Parameters ◽

Rake Angle ◽

Orthogonal Experimental Design ◽

Depth Of Cut ◽

Effective Parameters ◽

Factors Affecting ◽

The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

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An Investigation into the Effect of Electro-Contact Heating in the Machining of Low-Rigidity Thin-Walled Micro-Machine Parts

Materials ◽

10.3390/ma14164427 ◽

2021 ◽

Vol 14 (16) ◽

pp. 4427

Author(s):

Antoni Świć ◽

Arkadiusz Gola ◽

Olga Orynycz ◽

Karol Tucki

Keyword(s):

Control System ◽

Feed Rate ◽

Cutting Forces ◽

Flank Wear ◽

Cutting Speed ◽

Cutting Parameters ◽

Depth Of Cut ◽

Contact Heating ◽

Thin Walled ◽

Micro Machine

Low-rigidity thin-walled parts are components of many machines and devices, including high precision electric micro-machines used in control and tracking systems. Unfortunately, traditional machining methods used for machining such types of parts cause a significant reduction in efficiency and in many cases do not allow obtaining the required accuracy parameters. Moreover, they also fail to meet modern automation requirements and are uneconomical and inefficient. Therefore, the aim of provided studies was to investigate the dependency of cutting forces on cutting parameters and flank wear, as well as changes in cutting forces induced by changes in heating current density and machining parameters during the turning of thin-walled parts. The tests were carried out on a specially designed and constructed turning test stand for measuring cutting forces and temperature at specific cutting speed, feed rate, and depth of cut values. As part of the experiments, the effect of cutting parameters and flank wear on cutting forces, and the effect of heating current density and turning parameters on changes in cutting forces were analyzed. Moreover, the effect of cutting parameters (depth of cut, feed rate, and cutting speed) on temperature has been determined. Additionally, a system for controlling electro-contact heating and investigated the relationship between changes in cutting forces and machining time in the operations of turning micro-machine casings with and without the use of the control system was developed. The obtained results show that the application of an electro-contact heating control system allows to machine conical parts and semi-finished products at lower cutting forces and it leads to an increase in the deformation of the thin-walled casings caused by runout of the workpiece.

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The Experimental Investigation of the Effects of Different Chip Breaker Forms on the Cutting Forces

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.23.191 ◽

2007 ◽

Vol 23 ◽

pp. 191-194 ◽

Cited By ~ 2

Author(s):

Huseyin Gürbüz ◽

Adem Kurt ◽

I. Korkut ◽

Ulvi Şeker

Keyword(s):

Experimental Investigation ◽

Cutting Forces ◽

Manufacturing Industry ◽

Cutting Parameters ◽

Cutting Conditions ◽

Depth Of Cut ◽

Test Results ◽

Workpiece Material ◽

Chip Breaker ◽

Cutting Speeds

The objective of this paper is experimentally investigation of the effects of different chip breaker forms on the cutting forces according to various cutting parameters. AISI 1050 workpiece material, most used material in the manufacturing industry, and SNMG 120408R inserts and PSBNR 2525M12 tool holder have 75° approaching angle according to ISO 3685 are used in the experiments. Seven groups chip breaker form were used in the tests. The chip breaker forms are the coated inserts MA, SA, MS, GH and standard, and the uncoated inserts MS and standard. These inserts are Mitsubishi UC 6010 and UTI20T grade; correspond to ISO P30 and P15 grade, respectively. Machining tests were carried out by using five levels of cutting speeds (150, 200, 250, 300, 350 m/min), three levels of feed rate (0.15, 0.25, 0.35 mm/rev) and two levels of depth of cut (1.6, 2.5 mm). Cutting forces were measured using Kistler dynamometer. The test results show that the highest cutting force values were measured on SA, GH, MA forms, respectively. Complex chip breaker forms cause the increase of the cutting forces. Although the cutting forces on the uncoated inserts were partly small in light cutting conditions, it has increased on the uncoated inserts in heavy cutting conditions compared to coated inserts.

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EFFECT OF CUTTING PARAMETERS ON CUTTING FORCES IN TURNING OF CPM 10V STEEL

Journal of Production Engineering ◽

10.24867/jpe-2021-02-005 ◽

2021 ◽

Vol 24 (2) ◽

pp. 5-8

Author(s):

Anđelko Aleksić ◽

◽

Milenko Sekulić ◽

Marin Gostimirović ◽

Dragan Rodić ◽

...

Keyword(s):

Feed Rate ◽

Cutting Forces ◽

Cutting Speed ◽

Physical And Mechanical Properties ◽

Cutting Parameters ◽

Radial Force ◽

Depth Of Cut ◽

Feed Force ◽

Cnc Lathe ◽

Method Analysis

The objective of this paper is to investigate the effect of cutting parameters on cutting forces during turning of CPM 10V steel with coated cutting tool. Machining of CPM 10V steel and finding a suitable tool is very challenging due to its physical and mechanical properties, especially since the machining of this material has not been extensively researched. The experiments were carried out using an Index GU -600 CNC lathe and the cutting forces were measured in process. A three-factorial three-level experimental design was used for the experiments. Statistical method analysis of variance (ANOVA) is applied to study the effects of cutting speed, feed rate, and depth of cut on cutting forces. The results of this study show that depth of cut has the most significant effect on main force and radial force, while feed rate and cutting speed have the most significant effect on feed force. The developed model can be used in the machining industry to predict and analyze cutting parameters for optimal cutting forces.

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Cutting Force Modeling in Precision Turning 3J33 Alloy for Tool with Nose Radius

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.69-70.167 ◽

2009 ◽

Vol 69-70 ◽

pp. 167-171

Author(s):

Yuan Sheng Zhai ◽

Yu Wang ◽

Ying Chun Liang

Keyword(s):

Cutting Force ◽

Feed Rate ◽

Cutting Forces ◽

Cutting Parameters ◽

Multiple Correlation Coefficient ◽

Depth Of Cut ◽

Ratio Test ◽

Nose Radius ◽

Precision Turning ◽

Force Modeling

Based on experimental results, a predictive model with certain constraints of cutting parameters (feed rate and depth of cut) and nose radius for cutting forces is solved in precision turning 3J33 alloy. The proposed model is adequate with F-ratio test and multiple correlation coefficient of it. Regression analysis shows that depth of cut and feed rate influence the principal cutting force significantly. The goal of this study is to predict cutting forces under certain constraints of cutting parameters and nose radius.

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Analysis of Surface Roughness and Cutting Forces in Hard Turning of 42CrMo4 Steel using Taguchi and RSM Method

Mechanika ◽

10.5755/j01.mech.26.3.23600 ◽

2020 ◽

Vol 26 (3) ◽

pp. 231-241 ◽

Cited By ~ 1

Author(s):

Mustafa ÖZDEMİR ◽

Mehmet Tuncay KAYA ◽

Hamza Kemal AKYILDIZ

Keyword(s):

Surface Roughness ◽

Feed Rate ◽

Cutting Forces ◽

Tangential Force ◽

Cutting Speed ◽

Cutting Parameters ◽

Radial Force ◽

Depth Of Cut ◽

Machining Parameters ◽

Feed Force

In this study, effects of cutting speed (V), feed rate (f), depth of cut (a) and tool tip radius (R) on surface roughness (Ra, Rz, and Rt) and cutting forces (radial force (Fx), tangential force (Fy), and feed force (Fz)) in hard finish turning processes of hardened 42CrMo4 (52 HRC) material was investigated experimentally. Taguchi’s mixed level parameter design (L18) is used for the experimental design (2x1,3x3). The signal-to-noise ratio (S/N) was used in the evaluation of test results. By using Taguchi method, cutting parameters giving optimum surface roughness and cutting forces were determined. Regression analyses are applied to predict surface roughness and cutting forces. Analysis of variance (ANOVA) is used to determine the effects of the machining parameters on surface roughness and cutting forces. According to ANOVA analysis, the most important cutting parameters were found to be feed rate for surface roughness and depth of cut among cutting forces. By conducting validation experiments, optimization was seen to be applied successfully.

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Validation and optimization of cutting parameters for Ti-6Al-4V turning operation using DEFORM 3D simulations and Taguchi method

Manufacturing Review ◽

10.1051/mfreview/2021001 ◽

2021 ◽

Vol 8 ◽

pp. 5

Author(s):

Japheth Oirere Obiko ◽

Fredrick Madaraka Mwema ◽

Michael Oluwatosin Bodunrin

Keyword(s):

Cutting Force ◽

Feed Rate ◽

Cutting Forces ◽

Signal To Noise Ratio ◽

Cutting Speed ◽

Cutting Parameters ◽

Interface Temperature ◽

Depth Of Cut ◽

Optimization Of Cutting Parameters ◽

The Relationship

In this study, we show that optimising cutting forces as a machining response gave the most favourable conditions for turning of Ti-6Al-4V alloy. Using a combination of computational methods involving DEFORM simulations, Taguchi Design of Experiment (DOE) and analysis of variance (ANOVA), it was possible to minimise typical machining response such as the cutting force, cutting power and chip-tool interface temperature. The turning parameters that were varied in this study include cutting speed, depth of cut and feed rate. The optimum turning parameter combinations that would minimise the machining responses were established by using the “smaller the better” criterion and selecting the highest value of Signal to Noise Ratio. Confirmatory simulation revealed that using cutting speed of 120 m/min, 0.25 mm depth of cut and 0.1 mm/rev feed rate, the lowest cutting force of 88.21 N and chip-tool interface temperature of 387.24 °C can be obtained. Regression analysis indicated that the highest correlation coefficient of 0.97 was obtained between cutting forces and the turning parameters. The relationship between cutting forces and the turning parameters was linear since first-order regression model was sufficient.

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Modeling and Analysis of Cutting Forces in Hard Turning T250 Steel Using CBN Tools

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.154-155.694 ◽

2010 ◽

Vol 154-155 ◽

pp. 694-700

Author(s):

Yue Ding ◽

Xi Bin Wang ◽

Li Jing Xie ◽

Hao Yang

Keyword(s):

Cutting Force ◽

Analysis Of Variance ◽

Feed Rate ◽

Cutting Forces ◽

Hard Turning ◽

Cutting Speed ◽

Cutting Parameters ◽

Depth Of Cut ◽

Modeling And Analysis ◽

Feed Force

The objective of this paper is to study the cutting forces in hard turning T250 steel with CBN tools. Experiments based on the Box-Behnken design were conducted to develop the cutting forces models by response surface methodology (RSM). Significance tests of the model are performed by the analysis of variance (ANOVA). It is also discussed the effects of cutting parameters (cutting speed, feed rate and depth of cut) on the cutting force components. The results show that the models can fit experimental data via analysis of variance. The most important cutting parameter is depth of cut, followed by feed rate, while the effect of cutting speed can be neglected. Compared to cutting force and feed force, thrust force is the largest. In addition, the cutting forces generated by the uncoated tool are smaller than by the coated one due to tool wear.

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Improving the Economics of Machining PMMCs

10.1115/imece1999-0675 ◽

1999 ◽

Author(s):

Mariam S. El-Gallab ◽

Mateusz P. Sklad

Keyword(s):

Mathematical Model ◽

Surface Finish ◽

Experimental Work ◽

Feed Rate ◽

Tool Material ◽

Cutting Parameters ◽

Cutting Conditions ◽

Tool Geometry ◽

Depth Of Cut ◽

Optimum Cutting

Abstract It is the purpose of this paper to present a mathematical model for the prediction of surface finish during turning 20%SiC/Al particulate metal matrix composites (PMMCs). The surface finish relation to the cutting parameters (tool material, tool geometry, speed, feed rate and depth of cut) is further employed in a general form for tool life in order to arrive at optimum cutting parameters that would cost the least and yet meet the surface roughness requirements. A simple C++ program has been developed to find the optimum cutting conditions iteratively. The mathematical models quantify the results of an extensive experimental work on oblique turning of the SiC/Al PMMCs. The results of the experimental work reveal that increasing the feed rate up to 0.55 mm/rev. improves the tool wear rate. This is attributed to the reduced area of contact between the tool surface and the abrading SiC particles. Further increases in the feed rate results in tool failure by edge chipping. The optimum cutting conditions arrived at by the mathematical model yield 21–37% cost reduction when compared to the currently employed cutting parameters.

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Prediction of Surface Roughness and Optimization of Cutting Parameters in CNC Turning of Rotational Features

Engineering and Technology Journal ◽

10.30684/etj.v38i8a.928 ◽

2020 ◽

Vol 38 (8A) ◽

pp. 1143-1153

Author(s):

Yousif K. Shounia ◽

Tahseen F. Abbas ◽

Raed R. Shwaish

Keyword(s):

Surface Roughness ◽

Linear Regression ◽

Regression Model ◽

Linear Regression Model ◽

Feed Rate ◽

Cutting Parameters ◽

Spindle Speed ◽

Depth Of Cut ◽

Non Linear ◽

Optimization Of Cutting Parameters

This research presents a model for prediction surface roughness in terms of process parameters in turning aluminum alloy 1200. The geometry to be machined has four rotational features: straight, taper, convex and concave, while a design of experiments was created through the Taguchi L25 orthogonal array experiments in minitab17 three factors with five Levels depth of cut (0.04, 0.06, 0.08, 0.10 and 0.12) mm, spindle speed (1200, 1400, 1600, 1800 and 2000) r.p.m and feed rate (60, 70, 80, 90 and 100) mm/min. A multiple non-linear regression model has been used which is a set of statistical extrapolation processes to estimate the relationships input variables and output which the surface roughness which prediction outside the range of the data. According to the non-linear regression model, the optimum surface roughness can be obtained at 1800 rpm of spindle speed, feed-rate of 80 mm/min and depth of cut 0.04 mm then the best surface roughness comes out to be 0.04 μm at tapper feature at depth of cut 0.01 mm and same spindle speed and feed rate pervious which gives the error of 3.23% at evolution equation.

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