Optimization of Surface Quality and Power Consumption in Machining Hardened AISI 4340 Steel

Abstract

Hard turning has become an attractive method of machining for most manufacturers in the last few years due to its low cost and superior surface quality compared to grinding. In this experimental study, the machinability of hardened steel under dry machining on a CNC lathe is undertaken to optimize the cutting parameters for minimum surface roughness and energy consumption with the cutting speed (320, 450, and 575), tool type (coated and uncoated), and feed rate (0.1, 0.18, and 0.26) as the input parameters. The Taguchi method, based on the L18 orthogonal array, the variance analysis, the signal-to-noise ratios, and the response surface methodology have been used to optimize surface roughness (Ra) and cutting power (Cp). Optimum cutting parameters and levels were determined, and the relationship between cutting parameters and output variables was analyzed with the aid of two-dimensional and three-dimensional graphics. The results show that the most effective parameter on the surface roughness was the tool type (78%), while the most effective parameter on energy consumption was the cutting speed (90%). The combination of low feed rate and high cutting speed is necessary for minimizing the surface roughness. Besides, the impact of two-factor interactions of the feed rate-cutting speed and depth of cut-cutting speed appears to be substantial. The linear regression models were validated using confirmation tests. Finally, regression coefficients were determined as a mathematical model, and it was observed that this estimated model yielded results that were very similar to those achieved via real experiment (correlation values: 97.64% for surface roughness and 98.72% for energy consumption).

WASPAS Based Multi Response Optimization in Hard Turning of AISI 52100 Steel under ZnO Nanofluid Assisted Dual Nozzle Pulse-MQL Environment

“…The power consumption was greatly improved due to gaining speed as the motor consumed more power to rotate the workpiece at a higher speed [32]. Additionally, as the cutting speed increased, the mechanical and thermal load increased as well, which led to better power utilization [33]. Additionally, when the feed value increased, the amount of friction between the tool and work surface increased.…”

Study of Surface Roughness in Turning of Chromium-Molybdenum Steel

“…Дослідження [5][6][7][8][9][10] доводять, що шорсткість поверхні також залежить від режимів різання (подачі, швидкості різання, глибини різання) та параметрів різального інструменту (радіусу закруглення, головного та допоміжного кутів у плані), але дослідження подібного типу проводяться окремо для різних матеріалів, різального інструменту та режимів різання.…”