scholarly journals Optimization of Turning Process Parameters for Their Effect on En 8 Material Work piece Hardness by Using Taguchi Parametric Optimization Method

2012 ◽  
pp. 230-234
Author(s):  
Ashish Yadav ◽  
Ajay Bangar ◽  
Rajan Sharma ◽  
Deepak Pal
Keyword(s):  
Process Parameters ◽  
Tool Material ◽  
Optimization Method ◽  
Material Surface ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machining Parameters ◽  
Turning Process ◽  
Cylindrical Parts ◽  
Coated Carbide

A common method to manufacture parts to a specific dimension involves the removal of excess material by machining operation with the help of cutting tool. Turning process is the one of the methods to remove material from cylindrical and non-cylindrical parts. In this work the relation between change in hardness caused on the material surface due the turning operation with respect to different machining parameters like spindle speed, feed and depth of cut have been investigated. Taguchi method has been used to plan the experiments and EN 8 metal selected as a work piece and coated carbide tool as a tool material in this work and hardness after turning has been measured on Rockwell scale. The obtained experimental data has been analyzed using signal to noise and. The main effects have been calculated and percentage contribution of various process parameters affecting hardness also determined.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

Analysis of the Effect of Process Parameters for Circularity and Cylindricity Errors in Turning Process

2016 ◽  
Vol 852 ◽  
pp. 255-259 ◽  
Author(s):  
B. Singaravel ◽  
Chimmalagi Marulaswami ◽  
Thangiah Selvaraj
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Quality Criteria ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Work Piece ◽  
Turning Process ◽  
Machining Performance ◽  
Machining Operations

Turning is one of the fundamental machining operations and its process parameters leads to better machining performance. The economic benefit of turning operation is providing components with appropriate dimensional accuracy. In this work, the effects of process parameters on dimensional accuracy (circularity and cylindricity) parameters are analyzed in turning of EN25 steel. The process parameters considered are cutting speed, feed rate and depth of cut in order to minimize circularity and cylindricity. The result revealed that the minimum dimensional accuracy error values such as circularity and cylindricity are obtained in the combination of higher value of cutting speed and lower value of feed rate and depth of cut. This analysis is used to meet the machined work piece within the tolerance limit and improve the quality criteria.

scholarly journals Optimization on Cryogenic Co2 Machining Parameters of AISI D2 Steel using Taguchi Based Grey Relational Approach and TOPSIS

2018 ◽  
Vol 7 (3.12) ◽  
pp. 885 ◽  
Author(s):  
V Balaji ◽  
S Ravi ◽  
P Naveen Chandran
Keyword(s):  
Performance Measures ◽  
Process Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Influence Of Process Parameters ◽  
Aisi D2 Steel ◽  
Aisi D2 ◽  
Grey Relational ◽  
Coated Carbide ◽  
D2 Steel

The Machinability, and the process parameter optimization of Cryogenic CO2 machining operation for AISI D2 steel have been investigated  based on the Taguchi based grey approach and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS).In this examination work, the measure of the work materials utilized was AISI D2 Steel of size is 150mm × 50 mm × 50m with SANDWIK influence CVD To TiN coated carbide cutting insert tool device embed was utilized. The time taken for machining is 5 min and profundity of cut were kept up steady with various lower cutting velocities, and diverse encourage rate. An L27 orthogonal array was selected for planning the experiment. Cutting speed, depth of cut and feed rate were considered as input process parameters. Cutting force (Fz) and surface roughness (Ra) were considered as the performance measures. These performance measures were optimized for the improvement of machinability, quality of product. A comparison is made between the multi-criteria decision making tools. Grey Relational Analysis (GRA) and TOPSIS are used to confirm and prove the similarity. To determine the influence of process parameters, Analysis of Variance (ANOVA) is employed. The end results of experimental investigation proved that the machining performance can be enhanced effectively with the assistance of the proposed approaches.   

Studies on the Effect of Approach Angle and Process Parameters in Face Milling

2011 ◽  
Vol 110-116 ◽  
pp. 3147-3155
Author(s):  
Rao T. Sadasiva ◽  
K. Satyanarayana ◽  
Y. Praneeth ◽  
Anne Venu Gopal
Keyword(s):  
Tool Wear ◽  
Process Parameters ◽  
Face Milling ◽  
Machining Process ◽  
Process Time ◽  
Depth Of Cut ◽  
Work Piece ◽  
Approach Angle ◽  
Taguchi Design Of Experiments ◽  
Coated Carbide

Milling is the most widely applied machining process for producing flat surfaces and prismatic shapes. To minimize the process time and maximize the quality of the workpiece, it is essential to monitor the condition of cutting tool in machining operation and to optimize the process parameters. In the present investigations, experiments were performed on EN31 steel with un-coated carbide inserts in face milling with tools having different approach angles in order to determine the performance of the tool. The effects of process parameters namely speed, depth of cut and feed on tool wear of work piece were investigated. The cutting forces and tool wear are measured in order to evaluate the performance of the cutter. Acoustic emission signal was used for the online tool monitoring. A statistical technique, Taguchi design of experiments was used to optimize the machining process parameters such as speed, feed, depth of cut and approach angle.

scholarly journals Dry turning of X2CrNi18-09 using coated carbide tools: modelling and optimization of multiple performance characteristics

Mechanika ◽  
2019 ◽  
Vol 25 (6) ◽  
pp. 487-500
Author(s):  
Septi Boucherit ◽  
Sofiane Berkani ◽  
Mohamed Athmane Yallese ◽  
Abdelkrim Haddad ◽  
Salim Belhadi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Removal Rate ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machining Parameters ◽  
Coated Carbide

The present paper investigates the cutting parameters pertaining to the turning of X2CrNi18-09 austenitic stainless steel that are studied and optimized using both RSM and desirability approaches. The cutting tool inserts used are the CVD coated carbide. The cutting speed, the feed rate and the depth of cut represent the main machining parameters considered. Their influence on the surface roughness and the cutting force are further investigated using the ANOVA method. The results obtained lead to conclude that the feed rate is the surface roughness highest influencing parameter with a contribution of 89.69%.The depth of cut and the feed rate are further identified as the most important parameters affecting the cutting force with contributions of 46.46% and 39.04% respectively. The quadratic mathematical models presenting the progression of the surface roughness and the cutting force and based on the machining parameters considered (cutting speed, feed rate and depth of cut) were obtained through the application of the RSM method. They are presented and compared to the experimental results. Good agreement is found between the two sections of the investigation. Furthermore, the flank wear of the CVD-coated carbide tool (GC2015) is found to increase with both cutting speed and cutting time. A higher tool life represented by t=44min is observed at cutting speed, feed rate and depth of cut of 280m/min,0.08mm/rev and 0.2mm respectively. Moreover and at low cutting speeds, the formation of micro weld is noticed and leads to an alteration of the surface roughness of the work piece. Finally, optimizing the machining parameters with the objective of achieving an improved surface roughness was accomplished through the application of the Desirability Function approach. This enabled to finding out the optimal parameters for maximal material removal rate and best surface quality for a cutting speed of 350m/min, a feed rate of 0.088 mm/rev and a depth of cut of 0.9mm.  

An Investigation on Machining Power of EN-AC 48000 Aluminum Alloy Used in Automotive and Aerospace Industries

2009 ◽  
Vol 83-86 ◽  
pp. 704-710 ◽  
Author(s):  
H. Shahali ◽  
Hamid Zarepour ◽  
Esmaeil Soltani
Keyword(s):  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Dimensional Accuracy ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Essential Parameter ◽  
Cutting Velocity ◽  
Coated Carbide

In this paper, the effect of machining parameters including cutting velocity, feed rate, and tool material on machining power of EN-AC 48000 aluminium alloy has been studied. A L27 Taguchi's standard orthogonal array has been applied as experimental design to investigate the effect of the factors and their interaction. Twenty seven machining tests have been accomplished with two random repetitions, resulting in fifty four experiments. EN-AC 48000 is an important alloy in automotive and aerospace industries. Machining of this alloy is of vital importance due to build-up edge and tool wear. Machining power is an essential parameter affecting the tool life, dimensional accuracy, and cutting efficiency. Three types of cutting tools including coated carbide (CD 1810), uncoated carbide (H10), and polycrystalline diamond (CD10) have been used in this study. Statistical analysis has been employed to study the effect of factors and their interactions using ANOVA analysis. Moreover, optimal factor levels have been presented using signal to noise ratio (S/N) analysis. Also, regression model have been provided to predict the machining power. Finally, the results of confirmation tests have been presented to verify and compare the adequacy of the predictive models.

Machinability Analysis of Aluminum Alloy-Graphene Metal Matrix Composites Using Uncoated and DLC-Coated Carbide Insert

2017 ◽  
Author(s):  
J. Joel ◽  
M. Anthony Xavior
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Surface Hardness ◽  
Tool Material ◽  
Hot Extrusion ◽  
Cutting Parameters ◽  
Extrusion Process ◽  
Work Piece ◽  
Matrix Composites ◽  
Coated Carbide

Metal Matrix Composites (MMCs) based on Aluminum Alloys 2024, 6061 and 7075 reinforced with Graphene was fabricated using powder metallurgy process followed by hot extrusion process. The extruded samples were used for conducting the turning experiments to evaluate the machinability of the developed composites. Turning experiments were conducted in ACE Micromatic made CNC lathe as per the Design of Experiments (DOE) designed using L18 Taguchi’s mixed orthogonal array. Uncoated and DLC coated carbide inserts, along with three levels of cutting speeds, feed rates and depths of cut were considered for the turning experiments. During the experiments the cutting force generated was recorded “online” and subsequent to the experimentation the surface roughness generated on the work piece and the surface hardness for every trial were recorded. The influence of the cutting tool material and other cutting parameters on the machinability of composites was analyzed using ANOVA. The microstructural observation on the surface of the machined specimen reveals the detachment of reinforcement materials from the composite and their impact of the surface quality.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Analysis and optimisation of machinability behavior of GFRP composites using fuzzy logic

2015 ◽  
Vol 11 (1) ◽  
pp. 102-119 ◽  
Author(s):  
Jenarthanan Poornachary Mugundhu ◽  
Suresh Subramanian ◽  
Ajay Subramanian
Keyword(s):  
Fuzzy Logic ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Mechanical And Thermal Properties ◽  
Machining Parameters ◽  
End Mill ◽  
Gfrp Composites ◽  
Content Type ◽  
Useful Life

Purpose – Glass fibre reinforced plastics (GFRP) contain two phases of materials with drastically distinguished mechanical and thermal properties, which brings in complicated interactions between the matrix and the reinforcement during machining. Surface quality and dimensional precision will greatly affect parts during their useful life especially in cases where the components will be in contact with other elements or materials during their useful life. The purpose of this paper is to discuss the application of the Taguchi method with fuzzy logic to optimise the machining parameters for machining of GFRP composites with multiple characteristics. Design/methodology/approach – The machining tests were performed on a CNC milling machine using solid carbide (K10) End mill cutting tool with three different helix angles. Experiments were planned using Taguchi’s orthogonal array with the cutting conditions prefixed. Findings – The machining parameters, namely, helix angle of the end mill cutter, spindle speed, feed rate, depth of cut, and work piece fibre orientation (specially applied to the GFRP composites) were optimised with considerations of multiple response characteristics, including machining force, material removal rate, and delamination. The results from confirmation runs indicated that the determined optimal combination of machining parameters improved the performance of the machining process. Originality/value – Multi-response optimisation of machinability behaviour of GFRP composites using fuzzy logic has not been attempted previously.

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