Multi-Objective Optimization of Material Removal Rate and Tool Wear in Rough Honing Processes

Abstract

This study focuses on obtaining regression models for material removal rate and tool wear in rough honing processes. For this purpose, experimental tests were carried out according to a central composite design of experiments. Five different parameters were varied: grain size or particle size of abrasive, density of abrasive or abrasive concentration, pressure of the stones against the cylinder internal surface, tangential speed (in this case, corresponding to the rotation speed of the cylinder), and linear speed of the honing head. In addition, multi-objective optimization was carried out with the aim of maximizing the material removal rate and minimizing tool wear. The results show that, within the range studied, the material removal rate depends mainly on tangential speed, followed by grain size and pressure. Tool wear is directly influenced by density of abrasive, followed by pressure, tangential speed, and grain size. According to the multi-objective optimization, if the two responses are given the same importance, it is recommended that high grain size, high density, high tangential speed, and low pressure be selected. Linear speed has less influence on both responses studied. If the material removal rate is considered to be more preponderant than tool wear, then the same values should be considered, except for high pressure. If tool wear is preponderant, then lower grain size of 128 (ISO 6106) should be selected, and lower tangential speed of approximately 166 min−1. The other variables, density and pressure, would not change significantly from the first situation.

An energy efficiency-based optimization of the rough honing process of hardened 5150 alloy

“…Higher MRR with increased honing pressure was exhibited in the works of. 1,20,21 The MRR is relatively enhanced by 36.6% when the honing depth changes from 0.1 mm to 0.3 mm (Supplementary Figure 8d). Higher machining depth increases the honing force, leading to a greater vibration; hence, higher machined diameters are obtained.…”

“…Similar influences of the tangential speed on the MRR can be found in the works of. 1,20,21 As the linear speed changes from 4 m/min to 6 m/min, the MRR is relatively improved by 48.9% (Supplementary Figure 8b). An increased linear speed increases the velocity and vibration of the honing tool, resulting in higher deviations of the honed diameters; hence, the MRR increases.…”

“…The regression models of the TW and MRR of the rough honing operation were developed regarding the G , DE , L , T , and P , while the desirability approach was applied to find optimum data. 21 The authors stated that the G of 128 mesh, the T of 166 m/min, the DE of 75 (ISO 6104), and the P of 4.5 MPa could be applied to boost the honing performances.…”

Influence of Honing Parameters on the Quality of the Machined Parts and Innovations in Honing Processes

“…Yurdakul et al [15] stated that, even with only a few experiments, significant improvements in the conducted process could be obtained. The regression function is useful for developing optimization models of a honing process [178].…”

Advances and Trends in Non-Conventional, Abrasive and Precision Machining 2021

“…However, if MRR is deemed more crucial than tool wear, it is advised to maintain the same settings but opt for high pressure. On the other hand, if minimizing tool wear is prioritized, a lower grain size of 128 [1] and a reduced tangential speed of approximately 166 min −1 are recommended, while abrasive density and pressure remain relatively unchanged from the initial scenario. In the next work, the influence of the material type and the placement in the print chamber on the roughness of MJF-printed 3d objects is studied (Contribution 2).…”