scholarly journals Hard Turning ASSESSMENT on EN31 Steel in Dry and Wet Cooling Environments USING Grey-Fuzzy Hybrid Optimization APPROACH

2021 ◽  
Vol 13 (2) ◽  
pp. 55-62
Author(s):  
Saswat Khatai ◽  
◽  
Ramanuj Kumar ◽  
Ashok Kumar Sahoo ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Physical Vapor Deposition ◽  
Hard Turning ◽  
Removal Rate ◽  
Hybrid Optimization ◽  
Optimization Approach ◽  
Dry Cutting ◽  
Coated Carbide

In recent years, machining of hard-to-cut metals by hard turning process is an embryonic technology for machining industry and research development. Hard turning is generally defined as the material removal process of hardened steel having hardness greater than 45 HRC.  The current research presents a comparative hard turning investigation on EN 31 (56 ± 1 HRC) grade steel using physical vapor deposition (PVD) coated carbide tool under dry and wet cooling. The selection of a better cooling strategy among dry and wet cooling was based on the value of obtained surface roughness (Ra) and material removal rate (MRR) in hard turning. Wet cooling exhibited better performance over dry cutting as lower Ra and greater MRR are achieved with wet cooling. Further, considering Taguchi L16 orthogonal array, hard turning experiments were executed in wet cooling and responses like surface roughness (Ra), material removal rate (MRR), and diameter error were studied. Further, the Grey-fuzzy hybrid optimization tool was employed and found improved results relative to the alone grey relational analysis as about 9 % less Ra and 2.612 times more MRR is noticed at the grey fuzzy optimal set of parameters.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

scholarly journals Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

Materials ◽  
2019 ◽  
Vol 12 (22) ◽  
pp. 3749 ◽  
Author(s):  
Adel T. Abbas ◽  
Neeraj Sharma ◽  
Saqib Anwar ◽  
Faraz H. Hashmi ◽  
Muhammad Jamil ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Optimization Approach ◽  
High Speed Machining

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.

scholarly journals Optimal Seeking Surface Roughness and Material Removal Rate Responses of Hardened AISI 4340 High Strength Low AlloySteel in Dry Sustainable Environment

2021 ◽  
Vol 40 (1) ◽  
pp. 116-129
Author(s):  
Amar ul Hassan Khawaja ◽  
Mirza Jahanzaib ◽  
Shahzad Zaka
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
High Strength ◽  
Depth Of Cut ◽  
Sustainable Environment ◽  
Coated Carbide ◽  
Aisi 4340

The aim of this research is to study the machinability aspects of hardened AISI 4340 High Strength Low Alloy (HSLA) steel (50 ± 2 HRC (Hardness Rockwell C)). The experimental investigation using coated carbide inserts is carried out during the dry hard milling process in a sustainable environment. The input parameters in the study are speed, feed rate and depth of cut and the responses are Average surface Roughness (Ra) and Material Removal Rate (MRR) that are selected through screening. Central Composite Design (CCD) in response surface methodology has been utilized as the experimental design technique with twenty experiments. Analysis of variance has been employed to examine the momentous machining parameters and responses. A mathematical model has been developed to optimize the surface roughness and material removal rate. It has been observed that the most significant factor for Ra is feed rate while for MRR depth of cut is the most significant factor. The results show that the minimum value of Ra ~ 0.098 μm is achieved at speed ~ 1000 RPM, feed rate ~ 300 mm/min and depth of cut ~ 0.2 mm while the maximum value of MRR ~ 6.35 cm3/min is attained at feed rate ~ 500mm/min and depth of cut ~ 0.4 mm regarding less or no effect of speed ~ 500-1000 RPM. The average forecast error for the validation information has been observed to be 3.35%. for Ra and 3.2% for MRR. Further, it is investigated that good surface finish like grinding and dimensional accuracy can be achieved with coated carbide tools.

Study of Uncoated and Coated Carbide Insert on Tool Life, Surface Roughness and Material Removal Rate in Machining of EN27 steel

2015 ◽  
Vol 15 (2) ◽  
pp. 205-214
Author(s):  
Anil Ghubade ◽  
Ajay Gupta ◽  
Abhishek Abrol ◽  
Satsimran Singh
Keyword(s):  
Surface Roughness ◽  
Production Rate ◽  
Tool Life ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Coated Carbide ◽  
Carbide Insert

AbstractMetal cutting industries are facing challenges to increase production rate at minimum cost with improvement in quality in the final product. The increasing need of productivity, closed tolerance, dimensional stability and cost put tremendous pressure on manufacturing industries to design and develop new technologies to meet the required goal. Hence, coating over the existing tool plays an important role in achieving higher production rate, better tool life and minimization in cost. In this paper, we analyzed the effect of uncoated and coated carbide (triple and six layer coated) tool on tool life, surface roughness and material removal rate during dry turning of EN27 steel. Taguchi approach is used to find the best optimum parameter setting for turning of EN27 steel. A L9 orthogonal array, signal-to-noise ratio and ANOVA are applied to study machining parameters (Spindle speed, Feed rate and Depth of cut) in consideration of tool life (VB), material removal rate (MRR) and surface finish (Ra). The experimental investigation shows that the best machining performance is achieved by six layer coated carbide insert compared to uncoated and triple coated carbide insert under the selected machining conditions.

scholarly journals Use of Multi-Objective Optimization Technique (Taguchi-GRA Approach) in Dry Hard Turning of Inconel 625

2020 ◽  
Vol 12 (2) ◽  
pp. 133-142
Author(s):  
Chinmaya PADHY ◽  
Pariniti SINGH
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Removal Rate ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Grey Relational

Current developments in manufacturing industries consider developing a suitable optimization technique for achieving improved machining performance. This study investigates the optimum values of machining parameters required namely –cutting speed (v), feed rate (f) and depth-of-cut (d) during dry hard turning of Inconel 625 with the aim of enhancing the productivity by minimizing surface roughness (Ra), cutting force (Fc), whereas maximizing material removal rate(MRR). This kind of multi-response process variable (MRP) problems usually known as multi-objective optimizations (MOOs) are solved with the help of Taguchi- Grey Relational Approach (T-GRA). Thus, here is a study conducted to apply Taguchi and Grey relational analysis to optimize multiple performance characteristics during dry hard turning of Inconel -625. As a result, the attained process variables, viz., cutting speed (60 m/min), feed rate (0.3 mm/rev), depth- of- cut (0.25mm) lead to value of optimum response variables –mean cutting force (340 N), surface roughness (0.998 μm) and material removal rate (0.786 mm3/min). In this setup, PVD coated carbide tool inserts were used for dry hard machining (turning) operation.

scholarly journals Parametric Optimization for Cutting Forces and Material Removal Rate in the Turning of AISI 5140

Machines ◽  
2021 ◽  
Vol 9 (5) ◽  
pp. 90
Author(s):  
Mustafa Kuntoğlu ◽  
Osman Acar ◽  
Munish Kumar Gupta ◽  
Hacı Sağlam ◽  
Murat Sarikaya ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Cutting Forces ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Industrial Applications ◽  
Optimization Approach ◽  
Regression Equations ◽  
Dry Cutting ◽  
Optimum Parameters

The present paper deals with the optimization of the three components of cutting forces and the Material Removal Rate (MRR) in the turning of AISI 5140 steel. The Harmonic Artificial Bee Colony Algorithm (H-ABC), which is an improved nature-inspired method, was compared with the Harmonic Bee Algorithm (HBA) and popular methods such as Taguchi’s S/N ratio and the Response Surface Methodology (RSM) in order to achieve the optimum parameters in machining applications. The experiments were performed under dry cutting conditions using three cutting speeds, three feed rates, and two depths of cuts. Quadratic regression equations were identified as the objective function for HBA to represent the relationship between the cutting parameters and responses, i.e., the cutting forces and MRR. According to the results, the RSM (72.1%) and H-ABC (64%) algorithms provide better composite desirability compared to the other techniques, namely Taguchi (43.4%) and HBA (47.2%). While the optimum parameters found by the H-ABC algorithm are better when considering cutting forces, RSM has a higher success rate for MRR. It is worth remarking that H-ABC provides an effective solution in comparison with the frequently used methods, which is promising for the optimization of the parameters in the turning of new-generation materials in the industry. There is a contradictory situation in maximizing the MRR and minimizing the cutting power simultaneously, because the affecting parameters have a reverse effect on these two response parameters. Comparing different types of methods provides a perspective in the selection of the optimum parameter design for industrial applications of the turning processes. This study stands as the first paper representing the comparative optimization approach for cutting forces and MRR.

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