Investigation on surface defect machining of AISI 4340 steel

Jayakumar, N.; Senthilkumar, G.; Kumar, S. Vignesh

doi:10.1016/j.matpr.2022.05.001

Cited by 3 publications

(2 citation statements)

References 8 publications

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“…In SDM of hardened AISI 4340 steel, Jayakumar et al [5] investigated the effects of cutting parameters on machining force and surface roughness. The results showed that feed rate, followed by cutting speed and depth of cut, had the greatest impact on machining force.…”

Section: Introductionmentioning

confidence: 99%

Multi objective optimization of process parameters in hard turning of AISI 52100 steel with surface irregularities using GRA-PCA

Ponugoti,

Koka,

Dantuluri

2023

Eng. Res. Express

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Dry hard-turning is a cost-effective, efficient manufacturing method for AISI 52100 hardened bearing steel. Surface Defect Machining (SDM) is a novel approach to address surface roughness, deteriorations, residual stresses, and metallurgical changes on machined steel. SDM involves exposing workpieces to surface irregularities, reducing cutting resistance, and enhancing surface integrity and finish. In the present work, surface irregularities are formed on the surface of the workpiece in the form of indentations. Using the response surface method's central composite design (CCD), 32 experimental runs were conducted to determine the optimal process parameters by varying the cutting and tool geometry parameters while AISI52100 steel hard turning (HT). Due to its complexity, multi-objective optimization is more challenging to study.The present work aims to evaluate the effects of input parameters on maching force, surface roughness, and workpiece surface temperature. Further, machining parameters optimization is performed employing the Grey relational analysis integrated with principal component analysis (GRA-PCA). Analysis of variance (ANOVA) was used to examine the impact of cutting and tool geometry parameters on grey relational grade (GRG). ANOVA revealed that feed has the highest influence on GRG, followed by depth of cut, nose radius, cutting speed, and negative rake angle. Cutting speed of 800 rpm, feed rate of 0.04 mm/rev, depth of cut of 0.5 mm, nose radius of 1 mm, and negative rake angle of 15º are the optimum combination of process parameters.

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Section: Introductionmentioning

confidence: 99%

Multi objective optimization of process parameters in hard turning of AISI 52100 steel with surface irregularities using GRA-PCA

Ponugoti,

Koka,

Dantuluri

2023

Eng. Res. Express

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“…Defects that are formed during the manufacturing and further operation of a product may be characterized by large variations in shape, depth, or distribution on the product surface. The most important surface defects include scratches, grooves, cracks, craters, pitting, and burrs [ 3 , 4 ].…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Effectiveness of Removing Surface Defects by Brushing

et al. 2022

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The paper presents the results of a study on the effectiveness of removing surface defects by brushing. Damage to machine components usually begins on their surface or in the surface layer area. This determines the development of methods, conditions, and process parameters that will positively affect the stereometric and physical properties of the surface layer. Experiments were conducted in which surface defects were generated on a specially designed test stand. By controlling the load and speed of the defect generator it was possible to affect the geometry, depth, and width of the surface defect. A FEM simulation of the brushing treatment was carried out in order to determine the effect of fibers passing through a surface defect in the form of a groove with a small depth and width. It was shown that for certain conditions of brushing treatment, surface defects could be removed effectively. Moreover, the microhardness of the surface layer after the brushing process was analyzed. Changes in microhardness due to brushing reached up to 50 μm for EN AW-2024 aluminum alloy and up to 150 μm for AZ91HP magnesium alloy. The results demonstrated that brushing was an effective method for strengthening the surface layer and that the value of strengthening in the area of defects depended on the effectiveness of their removal.

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