Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

Shnfir, Mohamed; Olufayo, Oluwole A.; Jomaa, Walid; Songmené, Victor

doi:10.3390/ma12233974

Cited by 24 publications

(20 citation statements)

References 60 publications

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“…In turning operations, feed rate and nose radius of the cutting tool are the governing parameters that dominate the surface generation process, and thus the obtainable roughness [29][30][31]. It is well known that an insert with a conventional round nose geometry restricts the productivity of the turning process.…”

Section: Introductionmentioning

confidence: 99%

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

et al. 2020

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This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.

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Section: Introductionmentioning

confidence: 99%

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

et al. 2020

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“…According to the relevant literature, cutting force, 11 tool wear, 12 and surface roughness 13 are one of the research focuses of cutting, and they are directly related to the quality of products. 14 Cutting forces and surface roughness can be affected by chip thickness, tool angle, and cutting speed.…”

Section: Introductionmentioning

confidence: 99%

The researches concern the influence of the helix angle on the composite machining process

Jiang

Wang

Gao

et al. 2021

Composites and Advanced Materials

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Magnesium oxide-reinforced wood fiber composites (MgO/WF) are a new type of multifunctional material, which can be used in different occasions, such as shopping malls, hotels, and residential buildings. Referring to the relevant literature, there is no research on the milling performance of MgO/WF. In order to better understand the relevant knowledge of the processability of MgO/WF, three cutters with different helix angles were used in this experiment to carry out the cutting of MgO/WF, and the variation trend of its cutting force, tool wear, and surface roughness was measured. The results are as follows: First, under the same cutting parameters, the resultant force decreases with the increase of helix angle. Second, with the increase of helix angle, the tool wear was slightly improved. Third, the surface roughness (Ra) showed an increasing trend with the decrease of helix angle. In the end, when milling MgO/WF, better machined surface quality and less tool wear can be obtained by selecting the tool with larger helix angle.

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“…Promising for monitoring cutting operations is control of cutting power. Shnfir et al (2019) investigated the influence of the mechanical milling parameters of AISI 1045 hardened steel, milling configuration, edge preparation and hardness of the processed material on machinability indicators, such as the resulting cutting force, energy consumption and wear of the side tool. Shao et al (2004) described the cutting power model for face milling used in the strategy for updating the cutting power threshold for monitoring tool wear.…”

Section: Introductionmentioning

confidence: 99%

Machine-learning for automatic prediction of flatness deviation considering the wear of the face mill teeth

et al. 2020

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The acceptance of the machined surfaces not only depends on roughness parameters but also in the flatness deviation (Δfl). Hence, before reaching the threshold of flatness deviation caused by the wear of the face mill, the tool inserts need to be changed to avoid the expected product rejection. As current CNC machines have the facility to track, in real-time, the main drive power, the present study utilizes this facility to predict the flatness deviation—with proper consideration to the amount of wear of cutting tool insert’s edge. The prediction of deviation from flatness is evaluated as a regression and a classification problem, while different machine-learning techniques like Multilayer Perceptrons, Radial Basis Functions Networks, Decision Trees and Random Forest ensembles have been examined. Finally, Random Forest ensembles combined with Synthetic Minority Over-sampling Technique (SMOTE) balancing technique showed the highest performance when the flatness levels are discretized taking into account industrial requirements. The SMOTE balancing technique resulted in a very useful strategy to avoid the strong limitations that small experiment datasets produce in the accuracy of machine-learning models.

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Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

Cited by 24 publications

References 60 publications

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

The researches concern the influence of the helix angle on the composite machining process

Machine-learning for automatic prediction of flatness deviation considering the wear of the face mill teeth

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