Parametric design optimization of hard turning of AISI 4340 steel (69 HRC)

Rashid, Waleed Bin; Goel, Saurav; Davim, J. Paulo; Joshi, Shrikrishna N.

doi:10.1007/s00170-015-7337-2

Cited by 60 publications

(27 citation statements)

References 29 publications

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“…The similar conclusion was discussed in the work of Das et al [7]. Rashid et al [8] used L 16 orthogonal array design concept of Taguchi method for four factors associated with four levels to optimize machining parameters (v, f, d) while hard turning of AISI 4340 steel (69 HRC) with cubic boron nitride tool. Conclusion revealed that lower feed produces improved machined surface finish, but causes high tool wear, so the choice of a suitable feed must be determined by trade-off between the quality and cost consideration.…”

Section: Introductionsupporting

confidence: 62%

Experimental investigation, modelling and optimization in hard turning of high strength low alloy steel (AISI 4340)

Panda

Das

Dhupal

2018

Matériaux & Techniques

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The present study addresses the machinability investigation of high strength low alloy grade AISI 4340 steel with coated ceramic tools on surface roughness, tool wear, and economic analysis by considering the hard turning process parameters such as cutting speed, feed and depth of cut. Twenty seven set of trials according to full factorial design of experiments are conducted. Analysis of variance, multiple regression method, Taguchi method, desirability function approach and Gilbert’s technique are employed for parametric influence study, predictive modelling, response optimization, tool life estimation followed by cost analysis. Results indicated that feed and cutting speed are the most significant and crucial factors for hard turning operation in order to achieve minimum surface roughness of machined component as well as flank wear of cutting tool. Abrasions, adhesion followed by plastic deformation are the key wear mechanisms of coated ceramic insert, resulted 47 min of tool life under optimum cutting conditions and ensued lower total machining cost per part ($ 0.29 only) due to higher tool life, and reduced downtime that justifies cost effectiveness of hard turning. Novelty aspects, the current research work demonstrates the substitution of conventional, expensive and slow cylindrical grinding process, and proposes the most expensive CBN tool alternative using coated ceramic tools in hard turning process from techno-economical and ecological point of views in line with the industrial requirements.

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Section: Introductionsupporting

confidence: 62%

Experimental investigation, modelling and optimization in hard turning of high strength low alloy steel (AISI 4340)

Panda

Das

Dhupal

2018

Matériaux & Techniques

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“…Because surface roughness affects several functional attributes such as corrosion resistance, tribological characteristics, fatigue strength, and wear resistance of machined components, various researchers have employed methods which includes experimental, statistical, and analytical approaches in hard turning operation with various workpiece materials [18CrMo4, 42CrMo4, SEA8620, AISI 1040, 1045 for modeling and optimization using response surface methodology (RSM) (Elbah et al 2013;Hessainia et al 2013;Shihab et al 2014;Azam et al 2015;Meddour et al 2015;Bouzid et al 2015), Taguchi method (Gunay and Yucel 2013;Rashid et al 2016;Zerti et al 2016;Panda et al 2016;Das et al 2017a), ANN (Asiltürk and Çunkaş 2011;Pontes et al 2012;Asiltürk 2012;Mia and Dhar 2016), GRA (Sahoo and Sahoo 2013a;Kacal and Yildirim 2012;Senthilkumar et al 2014), GA (Batish et al 2014;Bouacha and Terrab 2016), and particle swarm optimization (PSO) (Stryczek and Pytlak 2014;Yue et al 2016) to attain the surface quality and dimensional finishing condition similar to costly cylindrical grinding. For example, Hessainia et al (2015) found that response surface methodology represents a powerful approach and can offer to scientific researchers as well industrial metal workers a helpful optimization procedure for various combinations of the workpiece and the cut material tool.…”

Section: Introductionmentioning

confidence: 99%

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Panda

Das

Dhupal

2017

Process Integr Optim Sustain

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The paper addresses the assessment, modeling, and optimization study of surface roughness in finish dry hard turning (FDHT) of AISI 4340 steel with coated ceramic tool by considering the cutting speed, axial feed, depth of cut, and nose radius as machining parameters. Thirty sets of longitudinal turning trials based on central composite (CCD) design of experiments (DOEs) are performed, and response surface methodology (RSM), particle swarm optimization (PSO), and finally, Gilbert's approach are subsequently applied for mathematical modeling, response optimization, tool life estimation, and economic analysis. Additionally, various diagnostic tests have been executed to check the statistical significance and validity, adequacy, effectiveness, and fitness of data of the proposed model using analysis of variance (ANOVA) and Anderson-Darling normal probability test. Results indicated that nose radius and feed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness is considered. The RSM model combined with PSO technique leads to minimum surface roughness value similar to cylindrical grinding of 0.2021 μm, corresponding to optimum process parameters: 220 m/min of cutting speed, 0.05 mm/rev of feed, 0.193 mm of depth of cut, and 1.6 mm of tool nose radius. Finally, under pre-cited optimum machining conditions, tool life was evaluated to perform cost analysis for the economical justification and feasibility of coated ceramic tools in hard turning. The total machining cost per piece is ensued to be lower ($0.34) as a consequence of higher tool life (44 min), reduction in downtime, and enhancement in savings, which finds economical benefits in hard turning. The novelty aspects of the present work are that (i) it demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing coated ceramic tool in hard turning processes considering technological, economical, and ecological aspects, which are helpful and efficient from industrial point of view and (ii) it contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-55 HRC.

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“…The dry hard turning tests were experimented by means of Taguchi L16 orthogonal array (OA) design which comprises of total 16 experimental runs of different combinations of process inputs such as cutting speed (v), feed (f) and depth of cut (d) respectively each at four levels [26,27,28,29]. The levels of depth of cut vary from 0.…”

Section: Cutting Parametersmentioning

confidence: 99%

Investigating Machinability in Hard Turning of AISI 52100 Bearing Steel Through Performance Measurement: QR, ANN and GRA Study

Panda¹,

Sahoo²,

Panigrahi³

et al. 2018

INT. J. AUTOMOT. MECH. ENG.

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The existing endeavor investigates on machinability characteristics through performance measurement of flank wear, surface quality and chip morphology during finish turning of AISI 52100 bearing steel (55 ± 1 HRC) under dry environment employing carbide insert coated along with various layers (TiN/TiCN/Al2O3). Secondly the influence of machining variables viz. cutting speed, feed rate and depth of cut on responses are assessed by ANOVA and modeled through quadratic regression and artificial neural network. Multiparametric optimization of cutting conditions has been obtained through Taguchi based grey relational analysis. Finally, tool life at ideal conditions has been evaluated through experiment. Based on the study, it is disclosed that coated carbide with multilayer insert outperformed during hard machining as wear at the flank surface and surface quality are within the benchmark cap of 0.3 mm and 1.6 microns respectively. From the chip morphology analysis, multilayer coated carbide insert generates lower temperature and maintains cutting edge sharpness and delays the growth of tool wear. ANN model using multilayered feed forward network yields accurate prediction of responses with minimum error percentage compared to QR model. The optimal parametric combination through GRA approach is found to be d1 (0.1 mm)-f1 (0.04 mm/rev)-v2 (110 m/min) and is greatly improved. Feed is the compelling aspect for multi-responses pursued by cutting speed. The tool life at optimized cutting condition is found to be approximately 19 minutes.

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Parametric design optimization of hard turning of AISI 4340 steel (69 HRC)

Cited by 60 publications

References 29 publications

Experimental investigation, modelling and optimization in hard turning of high strength low alloy steel (AISI 4340)

Experimental investigation, modelling and optimization in hard turning of high strength low alloy steel (AISI 4340)

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Investigating Machinability in Hard Turning of AISI 52100 Bearing Steel Through Performance Measurement: QR, ANN and GRA Study

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