Performance optimisation of the turning process along with multi-surface heating process

Abstract

Materials that are difficult to cut possess excellent qualities and machinability, though conventional machining techniques require additional energy to circumvent the problems associated with the turning process. In this study, heat-assisted turning of duplex stainless steel (SS) was carried out. Various heating techniques such as infrared (IR)-, ultraviolet (UV)- and hot air (HA)-assisted heating were adopted. The experiment used an L16 orthogonal array with the most significant parameters such as heating method, feed rate in millimetres per revolution (mm/rev), depth of cut (millimetres [mm]) and cutting speed (metres per minute [m/min])on the cutting force and surface roughness. The technique for order performance by similarity to ideal solution (TOPSIS) and grey relational analysis (GRA), were used to optimise the output performance. The results of TOPSIS showed that the 16th experimental combination, i.e., the HA heating method, with feed rate = 0.175 mm/rev, depth of cut = 0.1 mm and cutting speed = 150 m/min, required a smaller cutting force and resulted in lower surface roughness. In case of the GRA method, the best output performance was observed for the 15th experimental combination, that is, the HA heating method, with feed rate = 0.15 mm/rev, depth of cut = 0.2 mm and cutting speed = 200 m/min. Compared to the non–heat-assisted turning process, the HA- and UV-assisted processes required 10.25% and 7.69% lesser cutting force, respectively, and the surface roughness in case of the HA method was 15.13% lesser.