Numerical Modelling and Optimization of Dry Orthogonal Turning of Al6061 T6 Alloy

Sumesh, C.S.; Ramesh, Ajith

doi:10.3311/ppme.11347

Cited by 16 publications

(6 citation statements)

References 7 publications

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“…Response Surface Methodology is an analytical method used to assess the effect of multiple predictor variables on a response variable 24 , 28 – 30 . This approach involves creating a mathematical model that predicts the response variable based on different combinations of predictor variables to identify the combination of predictor variable values that optimizes or achieves the desired response 31 .…”

Section: Resultsmentioning

confidence: 99%

Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites

Selvam,

Subramanian,

Diviya

et al. 2023

Sci Rep

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The traditional way to machine hybrid composites is hard because they tend to break, have a high retraction, have a high service temperature, and have an uneven surface irregularity. For high-strength fiber/metal composite constructions, alternative machining methods have drawn interest as a solution to these problems. Current research focuses on enhancing the Abrasive Water Jet Machining process by optimizing its variables using a composite material of epoxy reinforced with silicon carbide, stainless steel wire mesh, and Kevlar. The variables assessed are the Nozzle-to-substrate gap (S), the Abrasive discharge molding and different percentages of silicon carbide (SiC) filler (0%, 3%, and 6% by weight), three different types of hybrid laminates (H1, H2, and H3) were produced. The response surface method (RSM) was utilized in this learning, specifically on a central composite design, to calculate and optimize machining variables based on the Kerf convergence ratio (Kt) and Surface irregularity (Ra) as responses. According to the results, the traverse feed velocity, Abrasive discharge proportion, and Nozzle-to-substrate gap are the critical factors in determining Surface irregularity and Kerf convergence width (H1 laminate) for a fiber/metal laminate with 0%, 3% and 6% weight fraction. In the case of a 3% weight fraction H2 laminate, the traverse feed velocity was identified as the primary factor affecting the Kerf convergence ratio. In contrast, traverse feed velocity and Nozzle-to-substrate gap had the most significant influence on Surface irregularity. The findings also indicated that S, followed by Abrasive discharge proportion and traverse feed velocity, are the variables that have the most significant influence when cutting 6 wt% SiC filler particle fiber/metal laminate (H3 laminate). For Surface irregularity, the combination of traverse feed velocity and Nozzle-to-substrate gap had the most significant impact. To validate the optimization results, confirmatory tests was conducted, and the findings were very similar to the experimental values, indicating the accuracy and effectiveness of the optimization process. To better understand the manufacturing processes, a scanning electron microscope was used to examine the morphological features of the machined surfaces, such as delamination, fibre breakage, and fibre pull-out.

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Section: Resultsmentioning

confidence: 99%

Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites

Selvam,

Subramanian,

Diviya

et al. 2023

Sci Rep

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“…The loading path used for groove formation is taken from the literature [9]. An additional step with no load acting on the tube is added near the end to reduce spring back and for better stress relaxation [17]. In Stage 2, the grooved tubes were blown up to take the final shape of the die.…”

Section: Interactions and Boundary Conditionsmentioning

confidence: 99%

“…Lower deformation displacements are solved using a Lagrangian approach in the mesh. Mesh adapts to the Eulerian approach for extensive material flow and solves for velocities [16][17][18][19][20][21].…”

Section: Interactions and Boundary Conditionsmentioning

confidence: 99%

Numerical Investigation on Influence of Grooves on Tube Hydroforming Process of Aluminium Alloys

Ramanathan,

Ramesh,

Achuthankutty

2024

Period. Polytech. Mech. Eng.

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For several decades, scientists and engineers have been using the tube hydroforming (THF) process for numerous applications in the automotive and aerospace industries. The inert advantages like weight reduction without compromising on strength, improved part quality, better surface finish, and reduced tooling costs have motivated the use of THF in the fabrication industry. The presence of grooves on the pre-forms was found to immensely help in increasing the pressure-withstanding capacity of the THF tubes, in addition to reducing the stress concentration and achieving the near-net shape during the THF process. This project involves the development of a detailed Finite Element Model, for the THF process. Numerical analysis is carried out in two stages: Stage-1: Groove Formation, and Stage-2: Final THF tube formation. In Stage 1, the numerical model investigates the formation of grooves, predicting the amount of internal pressure and axial feeding that are required to accurately form them. In Stage 2, numerical simulations focus on the actual THF process. This two-stage THF process (Grooved-THF) was compared to a single-stage Generic THF process. The results indicate the Grooved-THF to be producing a relatively lower thickness reduction with a more closely formed corner radius compared to the generic case. The work also involves multi-objective optimization of the process parameters like the number of grooves, coefficient of friction, internal fluid pressure, and die corner radius using the DOE technique – RSM. The results indicate the number of grooves and the friction coefficient to be the most influencing parameters in the THF process.

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“…It is necessary to utilize multi-response optimization in order to find a solution to this issue and improve the efficiency of the machining process [13][14][15]. For this reason, multi-response optimization algorithms such as the weight assignment method, response surface methodology grey relational analysis, technique for order of preference by similarity to ideal solution and Taguchidata envelopment analysis based ranking methodology (DEAR) analysis have been utilized for the purpose of optimizing the parameters [16][17][18][19][20]. The response surface methodology utilizes a more laborious data representation method, which calls for an increased number of tests [21].…”

Section: Introductionmentioning

confidence: 99%

Dry machining characteristics of coated inserts and multi response optimization through DEAR‐Taguchi method

Chinnasamy

Rathanasamy²

2023

Materialwissenschaft Werkst

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The primary intent of the proposed research work is to investigate the effectiveness of the titanium aluminium nitride/tungsten carbide‐carbide coated insert during dry turning structural stainless steel. The aim of the study is to simultaneously optimise machining variables like spindle speed, depth of cut and feed for several responses like flank wear, material removal rate and surface roughness. Titanium aluminium nitride/tungsten carbide‐carbide is coated on the surface of carbide tool by cathodic arc evaporation method. The characterization studies have been conducted to ensure the existence of coating material. Micro hardness of coated and pure inserts was tested, which confirms that titanium aluminium nitride/tungsten carbide‐carbide coated insert possesses 17.43 % augmented hardness over pure inserts. The machining was performed by adopting Taguchi experimental design. A multi‐response optimization approach was applied in this study that included ranking methodology based on data development analysis and Taguchi's design. The performance index for multiple responses was measured and mathematically analysed for their effect on processing parameters. The combination of parameter such as spindle speed: 2000 min−1; cutting depth: 0.45 mm and feed rate: 0.16 mm rev−1 was experimental as optimal machining parameters.

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Numerical Modelling and Optimization of Dry Orthogonal Turning of Al6061 T6 Alloy

Cited by 16 publications

References 7 publications

Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites

Effect of silicon carbide on kerf convergence and irregularity of the surface during abrasive water jet machining of fiber-metal hybrid composites

Numerical Investigation on Influence of Grooves on Tube Hydroforming Process of Aluminium Alloys

Dry machining characteristics of coated inserts and multi response optimization through DEAR‐Taguchi method

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