Effect of Wiper Edge Geometry on Machining Performance While Turning AISI 1045 Steel in Dry Conditions Using the VIKOR-ML Approach

Abstract

AISI 1045 can be machined well in all machining operations, namely drilling, milling, turning, broaching and grinding. It has many applications, such as crankshafts, rollers, spindles, shafts, and gears. Wiper geometry has a great influence on cutting forces (Fr, Ff, Fc and R), temperature, material removal rate (MRR) and surface roughness (Ra). Wiper inserts are used to achieve good surface quality and avoid the need to buy a grinding machine. In this paper, an optimization-based investigation into previously reported results for Taguchi’s based L27 orthogonal array experimentations was conducted to further examine effect of the edge geometry on the turning performance of AISI 1045 steel in dry conditions. Three input parameters used in current research include the cutting speed (Vc), feed (f) and depth of cut (ap), while performance measures in this research were Ra, Fr, Ff, Fc, R, temperature (temp) and MRR. The Vise Kriterijumska Optimizacija Kompromisno Resenje (VIKOR) method was used to normalize and convert all the performance measures to a single response known as the VIKOR-based performance index (Vi). The machine learning (ML) approach was used for the prediction and optimization of the input variables. A correlation plot is developed between the input variable and Vi using the ML approach. The optimized setting suggested by Vi-ML is Vc: 160 m/min; ap: 1 mm and f: 0.135 mm/rev, and the corresponding value of Vi was 0.2883, while the predicted values of Ra, Fr, Ff, Fc, R, temp and MRR were 2.111 µm, 43.85 N, 159.33 N, 288.13 N, 332,16 N, 554.4 °C and 21,600 mm3/min, respectively.

Optimization of Sustainable Carbon Steel Turning Parameters

“…ML-based correlation plots guide parameter optimization, suggesting optimal settings of Vc: 160 m/min, ap: 1 mm, and f: 0.135 mm/rev. Predicted values for Ra, cutting forces, temperature, and MRR align with optimized parameters, offering insights for enhancing AISI 1045 steel turning performance [17]. Abbas et al [18] investigated the effects of cutting conditions on machining AISI 1045 steel using wiper-shaped inserts.…”

“…These findings offer precise, cost-effective machining solutions for AISI 1045 steel [16]. Abbas et al [17] examined the effect of wiper geometry on AISI 1045 steel turning performance in dry conditions. Utilizing Taguchi-based L27 orthogonal array experiments, it optimizes cutting parameters; cutting speed, feed and depth of cut for surface roughness, cutting forces, temperature, and material removal rate (MRR).…”