scholarly journals Investigation of tool wear, surface roughness, sound intensity, and power consumption during hard turning of AISI 4140 steel using multilayer-coated carbide inserts

2021 ◽  
Vol 9 (4B) ◽  
Author(s):  
Abidin Şahinoğlu ◽  
◽  
Mohammad Rafighi ◽  
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Cutting Speed ◽  
Sound Intensity ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Aisi 4140 Steel ◽  
Aisi 4140 ◽  
Coated Carbide ◽  
Carbide Inserts

The present study investigated the machinability aspects, namely, surface roughness, sound intensity, power consumption, and crater wear, during dry turning of hardened AISI 4140 steel (63 HRC) employing (TiCN/Al2O3/TiN) multilayer-coated carbide inserts under dry cutting condition. The relationship between machining parameters and output parameters was determined using the Taguchi design. The analysis of variance was employed to evaluate the contributions of input parameters on output parameters. The main effect plots illustrated the impacts of cutting speed, feed, and depth of cut on response variables. Results show that the feed was the most dominant factor that affects surface roughness. Increasing the feed value increases the surface roughness, power consumption, and sound intensity. In the other part of this study, the constant values for feed (0.3 mm/rev), depth of cut (0.7 mm), and cutting speed (150 m/min) have been selected to evaluate a tool life that has 0.3 mm crater wear criteria. The results indicated that multilayer-coated carbide inserts presented very good tool life and reached 0.3 mm in 90 min. The experimental study results showed that chipping and abrasion were found to be the significant wear mechanism during hard turning of AISI 4140 steel. The cutting speed was the most significant parameter on the tool wear, although high cutting speed results the good surface finish but adversely increases the tool crater wear.

scholarly journals Optimisation of the Machining of Stellite 6 PTA Hardfacing Using Surface Roughness

2010 ◽  
Vol 443 ◽  
pp. 227-231 ◽  
Author(s):  
Md Shahanur Hasan ◽  
Md Mazid Abdul ◽  
Richard E. Clegg
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Deposition Process ◽  
Depth Of Cut ◽  
High Corrosion Resistance ◽  
Turning Operations ◽  
Stellite 6 ◽  
Cutting Regimes ◽  
Coated Carbide ◽  
Carbide Inserts

Stellites are cobalt based super alloys. By virtue of their excellent physio-mechanical properties, stellites are highly regarded engineering materials. Stellites posses high corrosion resistance and wear resistance properties. This study investigates the Stellite deposition process and machinability of Stellite 6 deposited on steel subtrate. Stellite 6 was deposited onto a 4140 bar using a plasma transfer arc (PTA) system and machinability was assessed on the basis of surface roughness. A series of turning operations have been carried out on a conventional lathe using coated carbide inserts and surface roughness was evaluated by Stylus type Surtronic3+ instrument. The values of surface roughness were plotted against different cutting speed, feed rate and depth of cut to display the results in graphical forms. Optimal cutting regimes were established against the best values of surface roughness.

The Effect of Vortex Tube Air Cooling on Surface Roughness and Power Consumption in Dry Turning

2013 ◽  
Vol 310 ◽  
pp. 348-351 ◽  
Author(s):  
Hadi Abdul Salaam ◽  
Phoon Sin Ye ◽  
Zahari Taha ◽  
Tuan Muhammad Yusoff Shah Tuan Ya
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Feed Rate ◽  
Vortex Tube ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Air Cooling ◽  
Coated Carbide

This paper presents a study of the effect of Ranque-Hilsch vortex tube air cooling on surface roughness quality and power consumption when turning mild steel material with coated carbide cutting tool. The cutting parameters involved in this study were cutting speed, feed rate and depth of cut. The cutting speed and feed rate were fixed at 160 m/min and 0.28 mm/rev, while the depth of cut was varied from 1.0 to 4.0 mm. During the turning process, the cutting temperatures were measured using an infrared thermometer and the power consumption was measured using a power and harmonics analyzer. The machined parts surface roughnesses were measured using a surface roughness tester. The results show that cooling using the Ranque-Hilsch vortex tube air cooling reduces the cutting temperature and the power consumption, but the surface roughness results is better when cooling with environment air.

Investigation into Effect of Cutting Conditions on Surface Roughness while Dry Machining Al-11%Si and Al-11%Si-1% Bi Die Casting Alloy

2015 ◽  
Vol 1119 ◽  
pp. 617-621
Author(s):  
Mohsen Marani Barzani ◽  
Ahmed A.D. Sarhan ◽  
Saeed Farahani ◽  
Ramesh Singh
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cnc Machine ◽  
Die Cast ◽  
Cast Alloys ◽  
Experimental Trials ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Cutting Speeds

In this study, an experimental investigation was conducted to determine the effects of cutting speeds and feed rates on surface roughness in turning of the Al %11Si and Al-11%Si-1% Bi die cast alloys. Experimental trials carried out on a CNC machine using coated carbide inserts (PVD). Three different cutting speeds, 70, 130 and 250 m/min and three feed rates 0.05, 0.1 and 0.15 mm/rev were used with a 0.15 mm constant depth of cut for all experiments. Additionally scanning electron microscope (SEM) was employed to clarify the different types of silicon morphology. Results revealed that surface roughness increased with increasing feed rate from 0.05 to 0.15 mm/rev and decreased with increasing cutting speed from 70 to 250 m/min. The result showed that workpiece containing Bi had the best surface roughness with lamellar silicon shape in comparison with aluminium-silicon with flake-silicon shape.

scholarly journals Modeling and optimization of face milling process parameters for AISI 4140 steel

2018 ◽  
Vol 12 (1) ◽  
pp. 5-10 ◽  
Author(s):  
Gokhan Basar ◽  
Funda Kahraman
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Aisi 4140 Steel ◽  
Control Factors ◽  
Aisi 4140

In this study, the effect of cutting parameters such as the depth of cut, feed rate, cutting speed and the number of inserts on surface roughness were investigated in the milling of the AISI 4140 steel. The optimal control factors for surface quality were detected by using the Taguchi technique. Experimental trials were designed according to the Taguchi L18 (21x33) orthogonal array. The statistical effects of control factors on surface roughness have been established by using the analysis of variance (ANOVA). Optimal cutting parameters were obtained by using the S/N ratio values. The ANOVA results showed that the effective factors were the number of inserts and the feed rate on surface roughness. However, the depth of cut and the cutting speed showed an insignificant effect. Additionally, the First-order and Second-order regression analysis were conducted to estimate the performance characteristics of the experiment. The acquired regression equation results matched with the surface roughness measurement results. The optimal performance characteristics were obtained as a 0.5 mm depth of cut, 0.08 mm/rev feed rate, 325 m/min cutting speed and 1 number of inserts by using the Taguchi method. Additionally, the confirmation test results indicated that the Taguchi method was very prosperous in the optimization of the machining parameters to obtain the minimum surface roughness in the milling of the AISI 4140 steel.

scholarly journals ESTIMATING THE EFFECT OF MACHINING PARAMETERS ON SURFACE ROUGHNESS DURING MACHINING OF HARDENED EN24 STEEL USING COATED CARBIDE INSERTS

2014 ◽  
pp. 123-128
Author(s):  
Sudhansu Ranjan Das ◽  
Amaresh Kumar ◽  
Debabrata Dhupal ◽  
Kali Charan Rath
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Surface Roughness Parameters ◽  
Hardened En24 ◽  
Coated Carbide ◽  
The Relationship ◽  
Carbide Inserts

In the present study, an attempt has been made to evaluate the performance of multilayer coated carbide inserts during dry turning of hardened EN24 steel (47 HRC). The effect of machining parameters (depth of cut, feed and cutting speed) on surface roughness parameters (Ra and Rz) were investigated by applying ANOVA. The experiments were planned based on Taguchi’s L27 Orthogonal array design. Results showed that surface roughness parameters (Ra and Rz) are mainly influenced by feed and cutting speed, whereas depth of cut exhibits minimum influence on surface roughness (Rz) and neglegible influence in case of surface roughness (Ra). The experimental data were further anlyzed to predict the optimal range of surface roughness parameters (Ra and Rz). Finally, second order regression models were carried out to find out the relationship between the machining parameters and surface roughness parameters.

scholarly journals An investigation of cutting parameters effect on sound level, surface roughness, and power consumption during machining of hardened AISI 4140

2020 ◽  
Vol 21 (5) ◽  
pp. 523
Author(s):  
Abidin Şahinoğlu ◽  
Efehan Ulas
Keyword(s):  
Surface Roughness ◽  
Energy Consumption ◽  
Power Consumption ◽  
Feed Rate ◽  
Cutting Speed ◽  
Total Power ◽  
Depth Of Cut ◽  
Machining Time ◽  
Total Power Consumption ◽  
Aisi 4140

In recent years, the necessity for energy in the manufacturing industry has become an important problem because fossil fuel reserves are decreasing in order to produce energy. Therefore, the efficient use of energy has become an important research topic. In this study, energy efficiency is investigated in detail for sustainable life and manufacturing. AISI 4140 material with high hardness of 50 HRC hardness has been applied cryogenic process to improve mechanical and machinability properties. In this experiment study, the effects of feed rate (0.04, 0.08, 0.12 mm/rev), cutting speed (140, 160, 180 m/min), depth of cut (0.05, 0.10, 0.15 mm) and tool radius (0.4, 0.8) on energy consumption, surface roughness and sound intensity were investigated. Then, a new mathematical model with high accuracy was developed. Total power consumption was calculated by considering the instantaneous current value and machining time. As a result, it is found that good surface quality obtained when the feed rate is low, and the tool radius is high and the machining time is shortened, the energy consumption is reduced due to the increase in cutting speed, depth of cut and feed rate. Also, it is found that the tool radius has a limited effect on energy consumption, but low feed value increases energy consumption.

scholarly journals Determination of Surface Roughness Throughout CNC Turning of ASTM 316 Steel Expending Taguchi Method

2019 ◽  
Vol 8 (4) ◽  
pp. 3966-3969
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Cutting Speed ◽  
Sample Surface ◽  
Depth Of Cut ◽  
Workpiece Surface ◽  
Cnc Turning ◽  
Mathematical Analyses ◽  
Coated Carbide ◽  
Carbide Inserts

Plan of experiment involving Taguchi method got developed and executed to gauge impact of various machining variables (V, F and D) on surface roughness throughout CNC turning of ASTM 316 steel using coated carbide insert. Research findings through different mathematical analyses provided the effective guideline for choosing appropriate machine settings to realize surface roughness within the recommended range during stated turning operation. Ideal machining situations got determined to minimize the surface roughness (here surface roughness factors Ra with Rz ) in turning of the same. Feed remains observed as paramount momentous variable for workpiece surface roughness. Furthermore, cutting speed remains observed as subsequent paramount momentous variable for workpiece surface roughness. Additionally, depth of cut remains observed as least paramount momentous variable for workpiece surface roughness, Rz only, however, depth of cut got absolutely insignificant impression on Ra . Present investigation clearly reveals that multicoated carbide inserts performed splendidly at optimal machining variables combination of V = 150 m/min, F = 0.10 mm/rev with D = 0.4 mm. Calculated ideal limit of sample surface unevenness, Ra and Rz are 0.16 µm ≤ Ra ≤ 0.52 µm and 1.4 µm ≤ Rz ≤ 3.1 µm, respectively. Moreover, surface roughness, Ra is also within stipulated precarious limit of 1.5 µm (i.e. Ra < 1.5 µm) for turning with coated carbide inserts.

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.

Wear Behavior of Carbide Inserts in Face Milling TA19 Alloy

2012 ◽  
Vol 426 ◽  
pp. 339-343 ◽  
Author(s):  
Qiu Lin Niu ◽  
X.J. Cai ◽  
Zhi Qiang Liu ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Titanium Alloy ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Aircraft Engine ◽  
Face Milling ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Crater Wear ◽  
Stable Conditions ◽  
Carbide Inserts

As a typical high strength material, titanium alloy Ti-6Al-2Sn-4Zr- 2Mo-0.1Si (TA19) is used to manufacturing the compressor power-brake of aircraft engine and the aircraft skin. All the machining experiments were carried out on a CNC-milling center under the stable conditions of cutting speed, feed rate, and depth of cut. The performance and wear mechanisms of coated- and uncoated carbide tools have been investigated in this paper to evaluate the machinability of TA19 in face milling. The three tools used were PVD-TiN+TiAlN, CVD-TiN+Al2O3+TiCN and uncoated carbide inserts. The results indicated that PVD coating had the best performance than other tool materials in milling titanium alloy TA19, and the cutting force and the wear value were the smallest than that for CVD-coated and uncoated tools. The failure types of PVD-, CVD- and uncoated inserts were the crater wear and micro tipping; the crater wear and tipping; tipping. Abrasive wear and adherent wear were the predominant mechanism of PVD-TiN+TiAlN carbide insert in face milling TA19 alloy. For CVD- and uncoated carbide, adherent wear was predominant.

OPTIMIZATION OF PROCESS PARAMETERS AFFECTING CUTTING FORCE, POWER CONSUMPTION AND SURFACE ROUGHNESS USING TAGUCHI-BASED GRAY RELATIONAL ANALYSIS IN TURNING AISI 1040 STEEL

2021 ◽  
Author(s):  
MAHIR AKGÜN
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Cutting Force ◽  
Cutting Speed ◽  
System Optimization ◽  
Gray Relational Analysis ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Significance Level ◽  
Relational Analysis

This study focuses on optimization of cutting conditions and modeling of cutting force ([Formula: see text]), power consumption ([Formula: see text]), and surface roughness ([Formula: see text]) in machining AISI 1040 steel using cutting tools with 0.4[Formula: see text]mm and 0.8[Formula: see text]mm nose radius. The turning experiments have been performed in CNC turning machining at three different cutting speeds [Formula: see text] (150, 210 and 270[Formula: see text]m/min), three different feed rates [Formula: see text] (0.12 0.18 and 0.24[Formula: see text]mm/rev), and constant depth of cut (1[Formula: see text]mm) according to Taguchi L18 orthogonal array. Kistler 9257A type dynamometer and equipment’s have been used in measuring the main cutting force ([Formula: see text]) in turning experiments. Taguchi-based gray relational analysis (GRA) was also applied to simultaneously optimize the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]). Moreover, analysis of variance (ANOVA) has been performed to determine the effect levels of the turning parameters on [Formula: see text], [Formula: see text] and [Formula: see text]. Then, the mathematical models for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) have been developed using linear and quadratic regression models. The analysis results indicate that the feed rate is the most important factor affecting [Formula: see text] and [Formula: see text], whereas the cutting speed is the most important factor affecting [Formula: see text]. Moreover, the validation tests indicate that the system optimization for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) is successfully completed with the Taguchi method at a significance level of 95%.

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