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.

scholarly journals Machining force comparison for surface defect hard turning and conventional hard turning of AISI 52100 steel

2021 ◽  
Vol 13 (3) ◽  
pp. 205-214
Author(s):  
P. U MAMAHESWARRAO ◽  
D. RANGARAJU ◽  
K. N. S. SUMAN ◽  
B. RAVISANKAR
Keyword(s):  
Hard Turning ◽  
Surface Defect ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 52100 ◽  
Machining Force ◽  
Aisi 52100 Steel ◽  
The Impact

In this article, a recently developed method called surface defect machining (SDM) for hard turning has been adopted and termed surface defect hard turning (SDHT). The main purpose of the present study was to explore the impact of cutting parameters like cutting speed, feed, depth of cut, and tool geometry parameters such as nose radius and negative rake angle of the machining force during surface defect hard turning (SDHT) of AISI 52100 steel in dry condition with Polycrystalline cubic boron nitride (PCBN) tool; and results were compared with conventional hard turning (CHT). Experimentation is devised and executed as per Central Composite Design (CCD) of Response Surface Methodology (RSM). Results reported that an average machining force was decreased by 22% for surface defect hard turning (SDHT) compared to conventional hard turning (CHT).

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.

Energy Cost Optimization in High Speed Hard Turning Using Simulated Annealing Algorithm

2015 ◽  
Vol 1115 ◽  
pp. 104-108
Author(s):  
Muataz Hazza F. Al Hazza ◽  
Erry Y.T. Adesta ◽  
Muhammad Hasibul Hasan ◽  
Norhashimah Shaffiar
Keyword(s):  
Simulated Annealing ◽  
Energy Cost ◽  
High Speed ◽  
Hard Turning ◽  
Simulated Annealing Algorithm ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Annealing Algorithm

Selecting the cutting conditions to optimize the economics of machining process as assessed by energy machining cost is essential. The aim of this research is to determine the optimum cutting parameters that minimize the energy cost needed for removing one cubic centimetre of material in High Speed Hard Turning (HSHT) process. To achieve that, a set of experimental machining data to cut hardened steel AISI 4340 was obtained with different ranges of cutting speed, feed rate, depth of cut and negative rake angle using mixed ceramic as a cutting tool. Regression models have been developed by using Box-Behnken design as a design of experiment. Then, the Simulated Annealing Algorithm (SAA) has been used to optimize the cutting parameters. The data collected was statistically modelled. The results show that the range of minimum energy cost to remove one cubic centimetre of material for the three techniques can be achieved in the range of 300 to 308 as a cutting speed, -12 for cutting rake angle, 0.125 as a feed rate and 0.15 as a depth of cut.

Effect of Cutting Parameters on Surface Texture of Flame Sprayed Coatings

2013 ◽  
Vol 199 ◽  
pp. 396-401
Author(s):  
Robert Starosta
Keyword(s):  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Clearance Angle ◽  
Approach Angle ◽  
Cutting Inserts

Coatings were turned by two tools: a) ISO 2R 2525K10, geometry and cutting parameters recommended by Messner Eutectic Castolin Company (tool angle β = 90o, approach angle κr = 45o, nose radius rε =0,8 mm, clearance angle α = 6o, rake angle γ = -5o) b) bit tool with CBN WNGA080408S01030A insert mounted in DWLNRL-2525M08 holder (cutting inserts β = 80o, approach angle κr = 95o, nose radius 0,8 mm, clearance angle α = 6o, rake angle γ = -6o). The influence of cutting speed, feed rate, depth of turning on the coating surface roughness was estimated. The following cutting parameters: cutting speed Vc = 45 214 m/min, feed rate f = 0,04 0,196 mm/rev, depth of cut ap = 0,05 0,3 mm. The lowest value of the roughness Ra = 0,5μm of the coatings were obtained by using cutting tools and parameters and bit tool: Vc = 214 m/min, f = 0,06 mm/rev, ap = 0,3 mm.

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.

scholarly journals Application of TOPSIS for multi response optimization of Process Parameters in dry hard turning of AISI 52100 steel

2021 ◽  
Vol 13 (1) ◽  
pp. 211-224
Author(s):  
P. UMAMAHESWARRAO ◽  
D. RANGARAJU ◽  
K. N. S. SUMAN ◽  
B. RAVISANKAR
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Hard Turning ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Workpiece Surface ◽  
Aisi 52100 ◽  
Machining Force ◽  
Aisi 52100 Steel

In the present work by employing the Technique for order of preference by similarity to ideal solution (TOPSIS) machining parameters optimization is performed with polycrystalline cubic boron nitride (PCBN) tools while AISI 52100 steel hard turning (HT). Based on the CCD of RSM, 32 experimental runs were performed by varying cutting speed, feed, depth of cut, nose radius, and negative rake angle to identify the optimal level of the process parameters. In this study, the multiple performance characteristics measured are machining force, surface roughness, and workpiece surface temperature. To ascertain the impact of cutting parameters on responses, Analysis of Variance (ANOVA) was deployed. An optimum combination of input process parameters for the multiple performance characteristics should be as follows: speed 200 rpm, feed 0.1 mm/rev, depth of cut 0.8 mm, nose radius 1.2 mm, and negative rake angle 45º leading to the value of optimum response variables machining force 561.163 N, Surface roughness 0.507μm and workpiece surface temperature 84.38°C.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Development of Tooling Cost Model for High Speed Hard Turning

2011 ◽  
Vol 418-420 ◽  
pp. 1482-1485 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz Al Hazza ◽  
Delvis Agusman ◽  
Agus Geter Edy Sutjipto
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Hard Turning ◽  
Cost Model ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Predictive Regression ◽  
Aisi 4340

The current work presents the development of cost model for tooling during high speed hard turning of AISI 4340 hardened steel using regression analysis. A set of experimental data using ceramic cutting tools, composed approximately of Al2O3 (70%) and TiC (30%) on AISI 4340 heat treated to a hardness of 60 HRC was obtained in the following design boundary: cutting speeds (175-325 m/min), feed rate (0.075-0.125 m/rev), negative rake angle (0 to -12) and depth of cut of (0.1-0.15) mm. The output data is used to develop a new model in predicting the tooling cost using in terms of cutting speed, feed rate, depth of cut and rake angle. Box Behnken Design was used in developing the model. Predictive regression model was found to be capable of good predictions the tooling cost within the boundary design.

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

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.

A Study of Relation between Roundness and Cutting Force in CNC Turning Process

2015 ◽  
Vol 799-800 ◽  
pp. 366-371 ◽  
Author(s):  
Deuanphan Chanthana ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
Nose Radius ◽  
Cnc Turning ◽  
Cnc Turning Process ◽  
Tool Nose Radius

The roundness is one of the most important criteria to accept the mechanical parts in the CNC turning process. The relations of the roundness, the cutting conditions and the cutting forces in CNC turning is hence studied in this research. The dynamometer is installed on the turret of the CNC turning machine to measure the in-process cutting force signals. The cutting parameters are investigated to analyze the effects of them on the roundness which are the cutting speed, the feed rate, the depth of cut, the tool nose radius and the rake angle. The experimentally obtained results showed that the better roundness is obtained with an increase in cutting speed, tool nose radius and rake angle. The relation between the cutting parameters and the roundness can be explained by the in-process cutting forces. It is understood that the roundness can be monitored by using the in-process cutting forces.

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