Towards an Adaptive Design of Quality, Productivity and Economic Aspects When Machining AISI 4340 Steel With Wiper Inserts

Abbas, Adel T.; Abubakr, Mohamed; Elkaseer, Ahmed; Rayes, Magdy M. El; Hegab, Hussien

doi:10.1109/access.2020.3020623

Cited by 13 publications

(8 citation statements)

References 48 publications

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“…The optimal results of MOGA and MOPSA are significantly close, while MOEPCA shows the best optimal results for the MRR but with a slightly higher surface roughness, which is undesirable. However, the obtained results, compared to [31], show moderate levels of cutting speed, low feed rates and higher depths of cut based on the selected parameter levels. Despite the similar results obtained from MOGA, MOPSA and MOEPCA of the wiper model, MOPSA outperformed the other two algorithms in computational time, as it was 30 times faster than MOGA and 20 times faster than MOEPCA.…”

Section: Optimization Resultsmentioning

confidence: 80%

“…The obtained cutting parameters considering the minimum surface roughness were a cutting speed of 155 m/min, a feed rate of 0.12 mm/rev and a depth of cut of 0.8 mm [ 30 ]. Furthermore, an adaptive approach was presented in which a multi-objective genetic algorithm was modified using linear techniques for multidimensional analysis of preference (LINMAP) [ 31 ]. The experimental work was carried out based on higher cutting speeds of up to 200 m/min using two different cutting inserts: wiper and conventional inserts.…”

Section: Introductionmentioning

confidence: 99%

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A Closer Look at Precision Hard Turning of AISI4340: Multi-Objective Optimization for Simultaneous Low Surface Roughness and High Productivity

et al. 2022

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This article reports an extended investigation into the precision hard turning of AISI 4340 alloy steel when machined by two different types of inserts: wiper nose and conventional round nose. It provides a closer look at previously published work and aims at determining the optimal process parameters for simultaneously minimizing surface roughness and maximizing productivity. In the mathematical models developed by the authors, surface roughness at different cutting speeds, depths of cut and feed rates is treated as the objective function. Three robust multi-objective techniques, (1) multi-objective genetic algorithm (MOGA), (2) multi-objective Pareto search algorithm (MOPSA) and (3) multi-objective emperor penguin colony algorithm (MOEPCA), were used to determine the optimal turning parameters when either the wiper or the conventional insert is used, and the results were experimentally validated. To investigate the practicality of the optimization algorithms, two turning scenarios were used. These were the machining of the combustion chamber of a gun barrel, first with an average roughness (Ra) of 0.4 µm and then with 0.8 µm, under conditions of high productivity. In terms of the simultaneous achievement of both high surface quality and productivity in precision hard turning of AISI 4340 alloy steel, this work illustrates that MOPSA provides the best optimal solution for the wiper insert case, and MOEPCA results are the best for the conventional insert. Furthermore, the results extracted from Pareto front plots show that the wiper insert is capable of successfully meeting both the requirements of Ra values of 0.4 µm and 0.8 µm and high productivity. However, the conventional insert could not meet the 0.4 µm Ra requirement; the recorded global minimum was Ra = 0.454 µm, which reveals the superiority of the wiper compared to the conventional insert.

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Section: Optimization Resultsmentioning

confidence: 80%

Section: Introductionmentioning

confidence: 99%

A Closer Look at Precision Hard Turning of AISI4340: Multi-Objective Optimization for Simultaneous Low Surface Roughness and High Productivity

et al. 2022

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“…Similar research was conducted using Wiper coated carbide insert by Kurniawan et al [19]. Abbas highlighted that using Wiper insert not only leads to superior surface integrity compared to conventional ones but also higher productivity can be achieved [20]. Nevertheless, it should be stated that hardness of materials has a significant impact for the tool life [21].…”

Section: Manufacturers Of Cutting Tools Do Not Providementioning

confidence: 78%

Analysis of the Impact of Wiper Geometry Insert on Surface Roughness and Chips in Machining Materials Used in the Aviation Industry

Szablewski¹,

Smak²,

Krawczyk³

2022

Adv. Sci. Technol. Res. J.

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Nowadays, great emphasis is placed on increasing the effi ciency of machining processes. However, this cannot be done at the expense of quality worsening of the machined surface. In this paper the infl uence of Wiper geometry on Ra and Rz surface roughness parameters is described when fi nishing turning of materials used in the aviation industry: austenitic stainless steel XCrNiNb18-9, low alloy steel 14NiCr14 and aluminum alloy A356, as well as the chips generated in the cutting process in terms of shape were assessed. It was found that for the lowest tested feed rate during turning with a Wiper insert, the values of Ra and Rz parameters do not diff er signifi cantly from the roughness parameters obtained during machining with a conventional insert. The benefi cial eff ect of feed rate on surface roughness for the Wiper insert is clearly visible above f ≥ 0.12 mm/rev. The biggest diff erence in roughness parameters was recorded for the highest value of the applied feed f = 0.28 mm/rev. Using conventional insert, Ra and Rz values are almost three times bigger than for Wiper insert. The infl uence of the cutting speed on the Ra and Rz parameters depends on the type of material being processed. Increasing cutting speed from v c =120 m/min to v c = 200 m/min for stainless steel, Ra and Rz values decrease about 35%. Similar situation noticed for aluminum alloy, but increasing cutting speed decrease Ra and Rz values only about 18%. The situation is diff erent for low alloy steel. Increasing the cutting speed increases the Ra and Rz parameters by about 37%. Rz/Ra ratio shows that for feed rate f ≤ 0.12 mm/rev. cutting process is unstable, because the values are between 5.5-7.5, but should oscillate around 4. Increasing feed rate value to f = 0.2 mm/rev allows to stabilize the process and the ratio value is close to 4. Wiper insert create the same form chips as a conventional insert, using the same value of feed rate.

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“…Researchers have reported that wiper inserts showed an excellent performance in terms of the surface quality at higher rates of feed compared to conventional inserts, though the process parameters [ 44 ] and cutting tool geometry [ 32 ] did affect the surface quality when using a wiper insert for hard turning. Although using wiper inserts enhanced the surface quality and increased productivity [ 35 ], it also showed higher tool rake wear, cutting force, and temperature compared with conventional inserts [ 17 , 21 ].…”

Section: Introductionmentioning

confidence: 99%

“…On the other hand, conventional inserts showed higher flank wear compared with the wiper inserts [ 13 , 31 ]. In addition, a recent work offered an adaptive design model to achieve a balance between the cost, productivity, and quality aspects when using wiper inserts [ 44 ].…”

Section: Introductionmentioning

confidence: 99%

Comparative Evaluation of Surface Quality, Tool Wear, and Specific Cutting Energy for Wiper and Conventional Carbide Inserts in Hard Turning of AISI 4340 Alloy Steel

et al. 2020

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This paper presents an experimental study into the comparative response of wiper and round-nose conventional carbide inserts coated with TiCN + AL2O3 + TiN when turning an AISI 4340 steel alloy. The optimal process parameters, as identified by pre-experiments, were used for both types of inserts to determine the machined surface quality, tool wear, and specific cutting energy for different cutting lengths. The wiper inserts provided a substantial improvement in the attainable surface quality compared with the results obtained using conventional inserts under optimal cutting conditions for the entire range of the machined lengths. In addition, the conventional inserts showed a dramatic increase in roughness with an increased length of the cut, while the wiper inserts showed only a minor increase for the same length of cut. A scanning electron microscope was used to examine the wear for both types of inserts. Conventional inserts showed higher trends for both the average and maximum flank wear with cutting length compared to the wiper inserts, except for lengths of 200–400 mm, where conventional inserts showed less average flank wear. A higher accumulation of deposited chips was observed on the flank face of the wiper inserts than the conventional inserts. The experimental results demonstrated that edge chipping was the chief tool wear mechanism on the rake face for both types of insert, with more edge chipping observed in the case of the conventional inserts than the wiper inserts, with negligible evidence of crater wear in either case. The wiper inserts were shown to have a higher specific cutting energy than those detected with conventional inserts. This was attributed to (i) the irregular nose feature of the wiper inserts differing from the simpler round nose geometry of the conventional inserts and (ii) a higher tendency of chip accumulation on the wiper inserts.

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Towards an Adaptive Design of Quality, Productivity and Economic Aspects When Machining AISI 4340 Steel With Wiper Inserts

Cited by 13 publications

References 48 publications

A Closer Look at Precision Hard Turning of AISI4340: Multi-Objective Optimization for Simultaneous Low Surface Roughness and High Productivity

A Closer Look at Precision Hard Turning of AISI4340: Multi-Objective Optimization for Simultaneous Low Surface Roughness and High Productivity

Analysis of the Impact of Wiper Geometry Insert on Surface Roughness and Chips in Machining Materials Used in the Aviation Industry

Comparative Evaluation of Surface Quality, Tool Wear, and Specific Cutting Energy for Wiper and Conventional Carbide Inserts in Hard Turning of AISI 4340 Alloy Steel

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