Multi-responses optimization in dry turning of a stainless steel as a key factor in minimum energy

Bagaber, Salem Abdullah; Yusoff, Ahmad Razlan

doi:10.1007/s00170-018-1668-8

Cited by 26 publications

(14 citation statements)

References 24 publications

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“…Reduction in EC with an increase in feed rate and/or cutting speed is logical because it results in faster machining and less processing time. 41 It is inferred from Figure 10(b) that an increased radius leads to an increment in cutting edge; hence, the cutting tool becomes blunt. The degree of the material deformation increases and more energy is required to overcome the resistance friction.…”

Section: Resultsmentioning

confidence: 98%

“…Fortunately, a higher value of F o r P e e r R e v i e w the feed rate or cutting speed leads to a decrease in the cutting time, resulting in a reduction in the energy consumed. Reduction in energy consumption with an increase in feed rate and/or cutting speed is logical because it results in faster machining and less processing time 41 . It is inferred from Fig.…”

Section: Parametric Effectsmentioning

confidence: 99%

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Green machining for the dry milling process of stainless steel 304

Nguyen

Mia

Dang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Dry machining represents an eco-friendly method that reduces the environmental impacts, saves energy costs, and protects operator health. This article presents a multi-response optimization which aims to enhance the power factor and decrease the energy consumption as well as the surface roughness for the dry machining of a stainless steel 304. The cutting speed ( V), depth of cut ( a), feed rate ( f), and nose radius ( r) were the processing conditions. The outputs of the optimization are the power factor, energy consumption, and surface roughness. The relationships between inputs and outputs were established using the radial basis function models. The experimental data were normalized, with the use of the Grey relational analysis. The principal component analysis is applied to calculate the weight values of technical responses. The desirability approach is used to observe the optimal values. The results showed that the technical outputs are primarily influenced by the feed rate and cutting speed. The reductions of energy consumption and surface roughness are approximately 34.85% and 57.65%, respectively, and the power factor improves around 28.83%, compared to the initial process parameter settings. The outcomes and findings of the investigated work can be used for further research in sustainable design and manufacturing as well as directly used in the knowledge-based and expert systems for dry milling applications in industrial practices.

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Section: Resultsmentioning

confidence: 98%

Section: Parametric Effectsmentioning

confidence: 99%

Green machining for the dry milling process of stainless steel 304

Nguyen

Mia

Dang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…They deduced that a cutting rate greater than 450 m/min yielded minimal cutting forces along with satisfactorily decreased chip thickness. Salem and Ahmad [ 202 ] optimized the design parameters, such that surface integrity and power consumption, of 316 SS under DM situation using Boron Nitride (BN) electrode. An RSM methodology was developed to validate the machining parameters.…”

Section: Discussionmentioning

confidence: 99%

Progressing towards Sustainable Machining of Steels: A Detailed Review

et al. 2021

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Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.

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“…Therefore, the high value of the original variable is represented by (+1), and the low value is represented by (−1). The (0) value represents the average of these two values (Bagaber and Yusoff 2018). BBD is renowned as one of the most common and efficient designs used in the RSM.…”

Section: Materials Propertiesmentioning

confidence: 99%

Optimization of geometric parameters of soil nailing using response surface methodology

et al. 2021

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Optimization of parameters of soil nailing is an important task in reinforcement soil problems. This paper focuses on the effect of nail geometric parameters on soil nailed wall analysis and identifies which factors that most affect their stability and cost using response surface methodology (RSM). RSM has been chosen to achieve an optimum combination of the soil nailing wall design. The influence of three factors has been considered; it included nail length, its inclination, and vertical spacing between nails. After a finite element analysis to model and perform the soil nailing simulations, a Box–Behnken design was applied, based on a set of experiments using various combinations. For this purpose, 15 runs were conducted to analyze tested parameters and to determine their interactions. The analysis of variance (ANOVA) and contour lines plots were investigated, and therefore, the most important parameters affecting the safety factor and the cost were identified. From the goodness-of-fit analyses of the model and the illustrative example, the proposed regression model provides a reasonably good estimate of the overall safety factor for soil nail walls and their cost. The results obtained from this study showed that RSM is an efficient and effective tool to identify the optimal combination, and it emerges that the safety factor and cost are most influenced by nail length and vertical spacing.

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Multi-responses optimization in dry turning of a stainless steel as a key factor in minimum energy

Cited by 26 publications

References 24 publications

Green machining for the dry milling process of stainless steel 304

Green machining for the dry milling process of stainless steel 304

Progressing towards Sustainable Machining of Steels: A Detailed Review

Optimization of geometric parameters of soil nailing using response surface methodology

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