Experimental study of surface roughness and geometrical and dimensional tolerances in helical milling of AISI 4340 alloy steel

Saadatbakhsh, Mohammad Hossein; Imani, Hadi; Sadeghi, Mohammad; Farshi, Sina Sabbaghi

doi:10.1007/s00170-017-0782-3

Cited by 20 publications

(19 citation statements)

References 21 publications

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“…With regard to workpiece hardness, hd, as it increases, the roughness decreases due to the lower deformation of the machined surface. The same behaviour was observed in the helical milling of AISI 4340 hardened steel [18]. The Rz results were graphically and statistically similar to Ra, the NNC multi-objective optimization method was applied.…”

Section: Roughness On Helical Milling Of Aisi H13 Hardened Steelsupporting

confidence: 66%

“…Some important results in this field are the case of helical milling of AISI D2 steel with 60 HRC [9], AISI D3 steel with 55 HRC [17] and AISI 4340 steel from 34 to 45 HRC [18].…”

mentioning

confidence: 99%

“…Since conventional hard drilling presents unfavourable conditions [36], helical milling is a practicable hole-making process which has been applied in these materials with good results [9,18].…”

mentioning

confidence: 99%

“…Workpiece hardness may present variation due to heat treatment, anisotropy, and other metallurgical characteristics. The effect of workpiece hardness was addressed in the helical milling of the AISI 4340 steel [18], nevertheless, it was not studied as a noise factor. The workpiece hardness has been studied as a noise factor in the context of hard machining [41].…”

mentioning

confidence: 99%

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Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Pereira

Silva

Lauro

et al. 2019

Applied Soft Computing

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Helical milling is a hole-making process which has been applied in hardened materials. Due to the difficulties on achieving high-quality boreholes in these materials, the influence of noise factors, and multi-quality performance outcomes, this work aims the multi-objective robust design of hole quality on AISI H13 hardened steel. Experiments were carried out through a central composite design considering process and noise factors. The process factors were the axial and tangential feed per tooth of the helix, and the cutting velocity. The noise factors considered were the tool overhang length, the material hardness and the borehole height of measurement. Response models were obtained through response surface methodology for roughness and roundness outcomes. The models presented good explanation of data variability and good prediction capability. Mean and variance models were derived through robust parameter design for all responses. Similarity analysis through cluster analysis was realised, and average surface roughness and total roundness were selected to multi-objective optimisation. Mean square error optimisation was performed to achieve bias and variance minimization. Multi-objective optimisation through normalized normal constraint was performed to achieve a robust Pareto set for the hole quality outcomes. The normalized normal constraint optimisation results outperformed the results of other methods in terms of evenness of the Pareto solutions and number of Pareto optimal solutions. The most compromise solution was selected considering the lowest Euclidian distance to the utopia point in the normalized space. Individual and moving range control charts were used to confirm the robustness achievement with regard to noise factors in the most compromise Pareto optimal solution. The methodology applied for robust modelling and optimisation of helical milling of AISI H13 hardened steel was confirmed and may be applied to other manufacturing processes. KeywordsHelical milling; AISI H13 hardened steel; Multi-objective robust optimization; Robust parameter design; Normalized normal constraint method. R 2 coefficient of determinationRadj 2 adjusted coefficient of determination Radj 2 prediction coefficient of determination

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Section: Roughness On Helical Milling Of Aisi H13 Hardened Steelsupporting

confidence: 66%

“…Some important results in this field are the case of helical milling of AISI D2 steel with 60 HRC [9], AISI D3 steel with 55 HRC [17] and AISI 4340 steel from 34 to 45 HRC [18].…”

mentioning

confidence: 99%

mentioning

confidence: 99%

mentioning

confidence: 99%

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Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Pereira

Silva

Lauro

et al. 2019

Applied Soft Computing

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“…in fatigue critical components. Some of the authors [13,18,19] have conducted their investigations on the AISI 4340 steel (as the equivalent of the OCHN3MFA), which is widely employed in automotive and aircraft industries, and in the manufacture of machine components, due to its advantageous combination of strength and toughness.…”

Section: Introductionmentioning

confidence: 99%

Material and technological investigation of machined surfaces of the OCHN3MFA steel

Barényi¹,

Majerík²,

Pokorny³

et al. 2020

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This paper deals with the effect of selected cutting parameter values in machining of OCHN3MFA steel on AFM and SEM microstructural analysis, cutting forces, nanohardness, 2D and 3D surface roughness, and material removal rate of surface layers after machining. OCHN3MFA steel was selected and used to perform experiments. Firstly, the selected steel was investigated before machining tests, due to the checking of the initial microstructure and chemical composition. The microstructure was performed on the Tescan Vega TS 5135 scanning electron microscope (SEM) with the X-ray microanalyzer Noran Six/300, and the Oxford Instruments MFP-3D Infinity atomic force microscope (AFM). Chemical composition was analyzed on Tasman Q4 surface analyzer. All machining tests of the used samples were performed under the selected cutting parameters in the SU 50A lathe machine tool with the CNMG 120408-M5 cementite carbide cutting insert clamped in the suitable DCLNR 2525M12-M cutting tool holder. During the machining process of testing samples, individual components of cutting forces were measured on a Kistler 9257B piezoelectric dynamometer with their subsequent evaluation using software Dynoware. Other experiments following the machining process were performed, evaluating the effect of selected cutting parameters on surface hardening. Surface hardening after machining of testing samples was subsequently measured on Hysitron TI950 Triboindenter with a Cube Corner measuring tip and evaluated by software Triboscan. 2D and 3D surface roughness and material removal rate (MRR) were finally performed on Talysurf CCI Lite and evaluated by software TalyMap Platinum.

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Tool wear in dry helical milling for hole-making in AISI H13 hardened steel

Pereira

Lauro

Brandão

et al. 2018

Int J Adv Manuf Technol

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Helical milling is a hole-making process which can be applied to achieve a high quality finished boreholes in hardened steels. Due to the drilling process limitations, which are intensified when applied in hardened steels, the helical milling process can be applied on hole-making tasks in moulds and dies industry, since milling have been widely applied in moulds and dies machining to replace high-cost operations like grinding and electrical discharge machining. However, to succeed in achieving high-quality boreholes in hardened parts, which presents high added value due to previous operations, tool wear in the helical milling of hardened steels should be more investigated. In the present study dry helical milling tool life tests were conducted in AISI H13 hardened steel parts, varying the cutting velocity. The flank wear on frontal cutting edges was progressively measured through optical microscopy, and SEM/EDS was performed in frontal and peripheral worn cutting edges. The wear occurred progressively in the flank of the frontal cutting edges with adhesion and oxidation as main wear mechanisms. In the peripheral edges, it was observed coating loss, adhesion of workpiece material in the tool clearance surface, besides fracture in the tool nose flank with the highest cutting velocity. A nested ANOVA was performed to evaluate the burr height in the borehole exit. The tool life stage was statistically significant in the burr height.

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Experimental study of surface roughness and geometrical and dimensional tolerances in helical milling of AISI 4340 alloy steel

Cited by 20 publications

References 21 publications

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Material and technological investigation of machined surfaces of the OCHN3MFA steel

Tool wear in dry helical milling for hole-making in AISI H13 hardened steel

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