Modeling and multiple optimization in face milling of hardfacing welding applied steel: Force, roughness, power

Abstract

The coating performance for indexable inserts is very important for the main machinability indicators such as energy consumption, cutting force, and surface quality, especially in milling operations. The present study intend to the comprehensive analysis of machining conditions for above mentioned machinability indicators that can be considered most important for sustainability in hard milling of a worn machine part. First, the worn zone of the shearing blade made of X40CrMoV5-1 hot work tool steel was filled with electric arc welding. Then, hard milling experiments were carried out to analyze the performance of different coated carbide inserts in the machining of the hardfacing welded part. Experiments were performed by applying L18 experimental design for invariable cutting depth, three different cutting speed, and feed rate with PVD-AlTiCrN and CVD-TiCN/Al2O3/TiN coated inserts. Machining parameters for the responses namely the resultant force (Fr), surface roughness (Ra), and cutting power (Pc) were simultaneously optimized via applying Taguchi-based grey relationship analysis. Finally, predictive models for the responses were developed by RSM. The results obtained by both coatings shown that the Fr and Ra are mainly influenced by the feed rate, while cutting speed is the parameter that most influenced the Pc. The optimum results with regards to the responses were obtained with the PVD-AlTiCrN coated tool. In the current study, the developed quadratic models and probability graphs indicated that the responses were highly predictable.

17-4PH Paslanmaz Çeliğin Kuru Ortamda Frezelenmesinde Kesme Parametrelerinin İşlenebilirlik Kriterlerine Etkilerinin Araştırılması

“…Energy consumption can be measured as well as calculated using cutting force data. Eq.2 is usually applied to calculate the power (in kW) required for removing the material in milling [23].…”

Understanding the Relationship between Surface Quality and Chip Morphology under Sustainable Cutting Environments

“…On the other side, poor thermal conductivity, extraordinary mechanical properties, ductility, and work hardening make the machinability of materials such as stainless steel difficult [4,5]. For these materials, selecting factors, for example, process parameters, cutting environment, and tool properties, are vital for optimizing machinability indicators such as surface properties, machining force, tool life, and consumed energy [6].…”

“…This force not only raises the cutting force and temperature, as well as causing material deformation, but also exacerbates tool wear and worsens the machined surface quality [11,12]. The cutting force is an essential machinability indicator for determining the loads and stress on tool and power consumption, and tool wear and surface integrity deteriorate when high [6,13]. At this point, MQL and nano-MQL cutting environments provide significant positive benefits on machinability outputs MQL cutting environments provide significant positive benefits on machinability outputs such as cutting forces, specific cutting energy, and tool wear compared to dry cutting in turning or milling applications [14][15][16].…”

On the Influence of Linear Energy/Heat Input Coefficient on Hardness and Weld Bead Geometry in Chromium-Rich Stringer GMAW Coatings

“…Comparing to other metal-coating techniques, WAAM coating application is efficient, since depending on the process circumstances it can reach from 1 kg up to 4 kg per hour, preserving 2 mm geometrical tolerancing and minimizing the welding defects [ 20 ]. However, when precise geometry is required, either additional machining (e.g., milling, grinding) might be necessary [ 21 ] or one has to carefully pick the technological parameters to achieve desired weld bead shape [ 22 ]. Examples of WAAM-fabricated products are presented on Figure 1 .…”