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.  

Taguchi Method Based Experiments of Titanium TC11 Flank Milling Parameters

2009 ◽  
Vol 407-408 ◽  
pp. 608-611 ◽  
Author(s):  
Chang Yi Liu ◽  
Cheng Long Chu ◽  
Wen Hui Zhou ◽  
Jun Jie Yi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Flank Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Mill Machining

Taguchi design methodology is applied to experiments of flank mill machining parameters of titanium alloy TC11 (Ti6.5A13.5Mo2Zr0.35Si) in conventional and high speed regimes. This study includes three factors, cutting speed, feed rate and depth of cut, about two types of tools. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of cutting force, cutting temperature and surface roughness. The analysis of result shows that the factors combination for good surface roughness, low cutting temperature and low resultant cutting force are high cutting speed, low feed rate and low depth of cut.

scholarly journals An Investigation on Optimum Process Parameters in Terms of Surface Roughness for Turning Titanium Alloy Ti-6Al-4V Using Coated Carbide

2019 ◽  
Vol 4 (4) ◽  
pp. 137-145
Author(s):  
Abdul Md Mazid ◽  
Md. Shahanur Hasan ◽  
Kazi Badrul Ahsan
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Real Life ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ti Alloys ◽  
Machined Parts ◽  
Coated Carbide ◽  
Coated Carbide Tools

The quality of machined parts and the productivity of machining that leads to economic sustainability.  These factors are also vital for machinability improvement for materials, as well as, for economically sustainable manufacturing. Due to their poor machinability titanium alloys (Ti-alloys) are categorised as difficult-to-machine materials. For the same reason products made of Ti-alloys are highly expensive and are used only in strategic and sophisticated industries.  A series of real-life experimental investigations was carried out to reveal the economic optimal zones of machining parameters that can produce the best possible surface roughness in machining Ti-6Al-4V alloy, using the coated carbide cutting tools, in shortest period of operation time. As the output of the research, for using the coated carbide tools for machining the investigated Ti-alloy, optimal zones of cutting speed, feed rate and depth of cut have been proposed and presented in graphical format. The current research revealed that all three groups (with nose radius Nr = 0.4, 0.8, and 1.2 mm) of coated carbide tools are capable to produce best surface finish, ranging between Ra = 0.5 - 1.0 µm, with cutting speed starting at V = 60 m/min and beyond at least up to V = 250 m/min while keeping the feed rate and depth of cut as constants as f = 0.1 mm/rev and d = 0.5 mm. The data on the graphs may help researchers, engineers and manufacturers to select optimal economic cutting speed, feed rate and depth of cut to achieve a certain level of surface roughness of machined components as assigned by the product designer on the part drawing. This reduces the production cost substantially, reduces number of defect products and improves product quality for machined parts.

Sensitivity Analysis and Optimization of Machining Parameters Based on Surface Roughness Prediction for AA6061

2014 ◽  
Vol 598 ◽  
pp. 181-188
Author(s):  
Elssawi Yahya ◽  
Guo Fu Ding ◽  
Sheng Feng Qin
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Original Data ◽  
Depth Of Cut ◽  
Work Piece ◽  
Surface Model ◽  
Machining Parameters ◽  
Machining System ◽  
The Relationship

Surface roughness is strongly affected by machining parameters. In the past few decades, many researchers have established the relationship between the surface roughness and machining parameters, but less attention has been paid to tool shape and geometry. In addition, the number of tool flutes was ignored, which affects in vibrations and machining system. Therefore, this study first-time includes the tool flutes in addition to cutting speed, depth of cut and feed rate as independent variables. Firstly, a set of machining experiments were conducted using AA6061 as a work piece material to provide original data. Response Surface Model (RSM) adopted to establish the relationship model of surface roughness and machining parameters using Minitab 16. Based on analysis of variance (ANOVA), the results show cutter flutes has higher significant followed by feed rate, depth of cut and cutting speed which has less significant. Finally, machining parameters were optimized to desired surface roughness, and optimization prediction error has limited values between-0.02 and 0.02μm.

Experimental investigations of cutting parameters’ influence on cutting forces and surface roughness in turning of Inconel alloy X-750 with biodegradable vegetable oil

2015 ◽  
Vol 231 (9) ◽  
pp. 1516-1527 ◽  
Author(s):  
Ahmadreza Hosseini Tazehkandi ◽  
Mohammadreza Shabgard ◽  
Farid Pilehvarian ◽  
Nakisa Farshfroush
Keyword(s):  
Surface Roughness ◽  
Vegetable Oil ◽  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Inconel Alloy ◽  
Coated Carbide

Nickel-based Inconel X-750 superalloy is widely applied in aerospace industry and manufacturing of gas turbine blades, power generators and heat exchangers due to its exclusive properties. As a consequence of low heat transfer coefficient and work-hardening properties, this alloy is known as a poorly machinable alloy. In this work, effect of machining parameters (cutting speed, feed rate and depth of cut) on cutting forces and surface roughness was investigated during turning of Inconel alloy X-750 with coated carbide tool. In order to meet the demands of the environment-friendly cutting processes and human health, biodegradable vegetable oil (BioCut 4600) was selected as the cutting fluid. The results were analyzed using response surface methodology and statistical analysis of variance, and mathematical models for cutting forces and surface roughness were proposed. Results indicated that feed rate and cutting speed were the most effective parameters on the surface roughness. However, depth of cut was the most effective parameter on cutting forces in comparison with cutting speed and feed rate. Eventually, in order to achieve the main aims of industrial production in large amounts and green manufacturing, the ranges for the best cutting conditions were presented.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

scholarly journals Investigations on Surface Roughness and Tool Wear Characteristics in Micro-Turning of Ti-6Al-4V Alloy

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2998 ◽  
Author(s):  
Kubilay Aslantas ◽  
Mohd Danish ◽  
Ahmet Hasçelik ◽  
Mozammel Mia ◽  
Munish Gupta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Removal Rate ◽  
Cutting Speed ◽  
Small Diameter ◽  
Cutting Parameters ◽  
Ti6al4v Alloy ◽  
Depth Of Cut ◽  
Turning Process ◽  
Micro Turning

Micro-turning is a micro-mechanical cutting method used to produce small diameter cylindrical parts. Since the diameter of the part is usually small, it may be a little difficult to improve the surface quality by a second operation, such as grinding. Therefore, it is important to obtain the good surface finish in micro turning process using the ideal cutting parameters. Here, the multi-objective optimization of micro-turning process parameters such as cutting speed, feed rate and depth of cut were performed by response surface method (RSM). Two important machining indices, such as surface roughness and material removal rate, were simultaneously optimized in the micro-turning of a Ti6Al4V alloy. Further, the scanning electron microscope (SEM) analysis was done on the cutting tools. The overall results depict that the feed rate is the prominent factor that significantly affects the responses in micro-turning operation. Moreover, the SEM results confirmed that abrasion and crater wear mechanism were observed during the micro-turning of a Ti6Al4V alloy.

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.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

scholarly journals Optimization of machining parameters in face milling using multi-objective Taguchi technique

2018 ◽  
Vol 12 (2) ◽  
pp. 104-108 ◽  
Author(s):  
Yusuf Fedai ◽  
Hediye Kirli Akin
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Taguchi Technique ◽  
Average Roughness ◽  
Multi Objective ◽  
Control Factors ◽  
Average Maximum

In this research, the effect of machining parameters on the various surface roughness characteristics (arithmetic average roughness (Ra), root mean square average roughness (Rq) and average maximum height of the profile (Rz)) in the milling of AISI 4140 steel were experimentally investigated. Depth of cut, feed rate, cutting speed and the number of insert were considered as control factors; Ra, Rz and Rq were considered as response factors. Experiments were designed considering Taguchi L9 orthogonal array. Multi signal-to-noise ratio was calculated for the response variables simultaneously. Analysis of variance was conducted to detect the significance of control factors on responses. Moreover, the percent contributions of the control factors on the surface roughness were obtained to be the number of insert (71.89 %), feed (19.74 %), cutting speed (5.08%) and depth of cut (3.29 %). Minimum surface roughness values for Ra, Rz and Rq were obtained at 325 m/min cutting speed, 0.08 mm/rev feed rate, 1 number of insert and 1 mm depth of cut by using multi-objective Taguchi technique.

Machining parameters effect in dry turning of AISI 316L stainless steel using coated carbide tools

2015 ◽  
Vol 231 (4) ◽  
pp. 676-683 ◽  
Author(s):  
Rusdi Nur ◽  
MY Noordin ◽  
S Izman ◽  
D Kurniawan
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Power Consumption ◽  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Machining Parameters ◽  
Aisi 316L ◽  
Coated Carbide

Austenitic stainless steel AISI 316L is used in many applications, including chemical industry, nuclear power plants, and medical devices, because of its high mechanical properties and corrosion resistance. Machinability study on the stainless steel is of interest. Toward sustainable manufacturing, this study also includes the power consumption during machining along with other machining responses of cutting force, surface roughness, and tool life. Turning on the stainless steel was performed using coated carbide tool without using cutting fluid. The turning was performed at various cutting speeds (90, 150, and 210 m/min) and feeds (0.10, 0.16, and 0.22 mm/rev). Response surface methodology was adopted in designing the experiments to quantify the effect of cutting speed and feed on the machining responses. It was found that cutting speed was proportional to power consumption and was inversely proportional to tool life, and showed no significant effect on the cutting force and the surface roughness. Feed was proportional to cutting force, power consumption, and surface roughness and was inversely proportional to tool life. Empirical equations developed from the results for all machining responses were shown to be useful in determining the optimum cutting parameters range.

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