An investigation on cutting sound effect on power consumption and surface roughness in CBN tool-assisted hard turning

Abstract

In machining activities, sound emission is one of the key factors toward the operator's health and safety. Sound generation during cutting is the outcome of the interaction between tool and work. The intensity of sound greatly influences the cutting power consumption and surface finish obtained during machining. Therefore, the current work emphasized the analysis of sound emission, power consumption, and surface roughness in hard turning of AISI 4340 steel using a CBN tool which was rarely found in the literature. Response surface methodology (RSM) and artificial neural network (ANN) techniques were utilized to formulate the model for each response. The results indicated that the maximum value of input parameters exhibited the highest level of sound due to the creation of vibration in the machine and tool. Higher sound level indicates the generation of lower power consumption but at the same instant surface roughness was leading with increment in sound level. The feed rate exhibited the utmost noteworthy consequence on surface quality with 87.71% contribution. The cutting power can be decreased by choosing the high level of cutting parameters. The RSM and ANN have a good correlation with experimental data, but the accuracy of the ANN is better than the RSM.

Assessment of performance parameters in intermittent turning and multi-response optimization of machining conditions using DF, MOORA, VIKOR, and coupled NSGAII-VIKOR methods

“…However, the factor (r) is not significant but still contributes with a cont% of 7.32%. Similar findings have been mentioned in [38,39]. The main effects of performance factors (Fz), (Az) and (Lp) as a function of variations in cutting parameters (Vc, r, ap and f) are illustrated in Figure (6).…”

A Comparative Performance Investigation of Single- and Double-Nozzle Pulse Mode Minimum Quantity Lubrication Systems in Turning Super-Duplex Steel Using a Weighted Pugh Matrix Sustainable Approach

“…For both cooling conditions (Figure 6c,d), the power consumption was leading with the depth of cut and feed rate, while the effect of pulse time was minor or irrelevant. Many other studies have observed similar findings, such as a considerable influence of feed and depth of cut on power consumption in machining [56,57]. Valeraa and Bhavsara [58] also concluded that the power consumption was gradually improved when the tool feed was improved in turning EN 31 grade steel.…”

Machinability Comparison of TiCN-Al2O3-TiN, TiAlN-TiN, and TiAlSiN Coated Carbide Inserts in Turning Hardened AISI 4340 Steel Using Grey-Crow Search Hybrid Optimization

“…For each tool, the cutting sound was rapidly enhanced with increasing speed due to the vibration and speed involved in hard turning. As indicated in many studies [53,54], the sound generation from machining was very sensitive to changes in the cutting speed. Many researchers agreed that the cutting sound was leading to an increasing cutting speed [55][56][57].…”

“…In the metal cutting industry, the cutting sound is considered to be an important health issue for individuals who are working around machining activities. This unpleasant sound had a significant influence on the hearing of the operators, as they spent at least 8 h per day in this noisy environment [53]. Therefore, to achieve sustainable machining, the cutting sound must be controlled to avoid damage to the hearing of workers present during that process.…”