New statistical models of cutting tool wear and cutting speed in turning 20MoCr130 stainless steel (original) (raw)
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In this study, we present experimental studies to research the effect of cutting parameters (cutting speed, feed rate and depth of cut) on tool life during the machining of AISI 304 stainless steel by using multi-coated carbide tool on CNC turning machine tools. High corrosion resistance, ductility and tension strength are the essential properties of stainless steels. Stainless steel is an alloy which has chrome, nickel and molybdenum elements and their machinability is negatively affected. For this reason, the machining of stainless steels is very difficult. In this study, the machining tests were carried out by using coated cutting tools. The tests were performed without coolant at various feed rates, cutting speeds and depth of cuts. Tool life, surface roughness and cutting forces have been determined experimentally. The effect of cutting parameters on the tool life has been researched. The relationship between cutting parameters and tool life was modeling with surface response m...
Research of Flank Wear in Turning of Stainless Steel
2011
The estimation of the reliability of the metal cutting tools represents a complex issue which depends on a number of factors: the process of cutting, geometric complexity, dynamic and thermal tensions. In this work are given the researched results of cutting tool flank wear P-30, during the turning of Stainless Steel X12CrNi18.8. The experiment is realized with the lathe machine IK62, whereas the wear measurement VB is done by microscope type JLC680148. For data process is used a statistic method with three factors.
In today's global market economy, producers have to produce high quality, low cost and more functional products as soon as possible in order to enable their assets to survive. One of the main factors in producing this high quality, low cost and functional product is the machinability factor. Work on the machinability of materials has been continuing with great acceleration in recent years. As a matter of fact, these studies provide not only the machinability but also the development of tool life and surface quality, and the formation of new material types. For this purpose, Korkut et al. (2004) studied AISI 304 stainless steels at different cutting speeds at constant cutting depth. At the end of the study, the increase of the cutting speed to a certain value causes the decrease of tool wear; but the increase in cutting speed after a certain value has increased the tool wear. (Korkut, Kasap et al., 2004) .Bh et al., in their work, have investigated the workability of AISI D3 hardened steel materials. The work was carried out using ceramic cutting tool without using cooling liquid. The effects of cutting parameters such as cutting speed, feed rate and cutting depth on tool wear and surface roughness were investigated. Three different cutting speeds, 3 different cutting depths and 3 different feed rates were used in the study, and the most important parameter on tool wear was cut depth (Varaprasad.Bh, Rao.Ch et al.) Wagh S.S. et al. have examined the machinability of AISI 304 stainless steels in their work. PVD plated carbide tool was used in the study. The cutting force and surface roughness and cutting temperature obtained during operation are measured. It has been determined that cutting force and surface roughness increase with the increase in working rate (Wagh, Kulkarni et al., 2013). Xavior M. A. et al.have investigated the effect of cooling liquid usage on surface roughness and tool wear during the machining of AISI 304 stainless steels. In the study, coconut oil was compared with 2 different cooling liquids. It has been determined that the use of cooling fluid in the work reduces surface roughness and tool wear. Coconut oil has been reported to provide more surface roughness and less tool wear than the other two cooling fluids used (Xavior and Adithan 2009). Debnath S. et al.have investigated the effects of different grades of cooling fluid and cutting parameters on surface roughness and tool wear. The study was carried out with a TiCN + Al2O3 + TiN plated tool on a CNC lathe using mild steel. It is stated that the parametres affecting the surface roughness are the rate of advancement and the most effective parameters in tool wear are cutting speed and cutting depth. It has been reported Abstract— In this work using AISI 304 non-corroding steel, the determination of the optimum cutting speeds from the machining parameters for cutting force, surface roughness, tool life and tool wear has been investigated. For this purpose, sawing operations have been carried out at low and high cutting speeds. Stainless steels contain elements such as chromium, nickel, and molybdenum added to the structure in order to impart different properties. Stainless steels have high corrosion resistance, ductility and tensile strength. Because of these features, defense industry is used intensively. The additional elements in the structure are those that affect the workability in the negative direction. Therefore, it is very difficult to process stainless steels. This work was carried out using a covered cutting tool without using cooling liquid at different cutting speeds. At the end of the study, tool life, tool wear, surface roughness and cutting forces were experimentally determined. The effect of cutting speed on cutting tool and machinability is examined.
The present work concerned an experimental study of turning on Austenitic Stainless steel of grade AISI 202 by a TiAlN coated carbide insert tool. The primary objective of the ensuing study was to use the Response Surface Methodology in order to determine the effect of machining parameters viz. cutting speed, feed, and depth of cut, on the tool wear of the machined material. The objective was to find the optimum machining parameters so as to minimize the tool wear for the selected tool and work materials in the chosen domain of the experiment. The experiment was conducted in an experiment matrix of 20 runs designed using a full-factorial Central Composite Design (CCD). Tool wears are measured with the help of a Toolmaker's microscope. The data was compiled into MINITAB ® 17 for analysis. The relationship between the machining parameters and the response variable (tool wear) were modeled and analysed using the Response Surface Methodology (RSM). Analysis of Variance (ANOVA) was used to investigate the significance of these parameters on the response variables, and to determine a regression equation for the response variables with the machining parameters as the independent variables, with the help of a quadratic model. Main effects and interaction plots from the ANOVA were obtained and studied along with contour and 3-D surface plots.
International Journal of Industrial Engineering Computations, 2018
The wear of cutting tools remains a major obstacle. The effects of wear are not only antagonistic at the lifespan and productivity, but also harmful with the surface quality. The present work deals with some machinability studies on flank wear, surface roughness, and lifespan in finish turning of AISI 304 stainless steel using multilayer Ti(C,N)/Al2O3/TiN coated carbide inserts. The machining experiments are conducted based on the response surface methodology (RSM). Combined effects of three cutting parameters, namely cutting speed, feed rate and cutting time on the two performance outputs (i.e. VB and Ra), and combined effects of two cutting parameters, namely cutting speed and feed rate on lifespan (T), are explored employing the analysis of variance (ANOVA). The relationship between the variables and the technological parameters is determined using a quadratic regression model and optimal cutting conditions for each performance level are established through desirability function approach (DFA) optimization. The results show that the flank wear is influenced principally by the cutting time and in the second level by the cutting speed. In addition, it is indicated that the cutting time is the dominant factor affecting workpiece surface roughness followed by feed rate, while lifespan is influenced by cutting speed. The optimum level of input parameters for composite desirability was found Vc1-f1-t1 for VB, Ra and Vc1-f1 for T, with a maximum percentage of error 6.38%.
HAL (Le Centre pour la Communication Scientifique Directe), 2015
The wear of cutting tools remains a major obstacle. The effects of wear are not only antagonistic at the lifespan and productivity, but also harmful with the surface quality. The present work deals with some machinability studies on flank wear, surface roughness, and lifespan in finish turning of AISI304 stainless steel using multilayerTi(C,N)/Al2O3/TiN coated carbide inserts. The machining experiments are conducted based on the response surface methodology (RSM). Combined effects of three cutting parameters, namely cutting speed, feed rate and cutting time on the two performance outputs (i.e. VB and Ra), and combined effects of two cutting parameters, namely cutting speed and feed rate on lifespan (T), are explored employing the analysis of variance (ANOVA).The relationship between the variables and the technological parameters is determined using a quadratic regression model and optimal cutting conditions for each performance level are established. The results show that the flank wear is influenced principally by the cutting time and in the second level by the cutting speed. In addition, it is indicated that the cutting time is the dominant factor affecting workpiece surface roughness followed by feed rate, while lifespan is influenced by cutting speed.
Statistical Approach for Behaviour of Cutting Parameters of Turning Operation
International journal of engineering research and technology, 2019
To produce any desired product, machining is one of the most important tasks. Through manipulating its system parameters, the difficulty of obtaining desired product can be accomplished. It can provide an effective method for determining optimal measuring parameters. The present examination applied Response Surface Methodology through a test study in straight turning of free cutting metal bar. The examination planned for assessing the best procedure condition which could at the same time fulfill prerequisites of both quality and just as profitability. At long last, the Optimization should be possible by many upgrading methods which pursues ANOVA to think about variety of advanced parameters. The information parameters considered in this work are cutting rate, feed, depth of cut and work material.
Tool wear investigation is very important for any industry to reduce the cost of production and maintain the quality of manufacturing. Tool life parameters help to understand the behavior of tool wear on different metals under varying conditions. In this project work, high speed steel has been used as the cutting tool and AISI 1040 steel, 6061 aluminium and ASTM A48 Grey cast iron as workpiece materials in turning operation on lathe machine. The experiment has been performed for different depths of cut such as 0.50 mm, 0.75 mm and 1.0 mm with the spindle speeds as 112 rpm, 225 rpm and 280 rpm. Feed rate has varied from 0.115 mm/rev to 0.138 mm/rev randomly. Cutting length of 20 cm has been kept constant under dry cutting condition for the whole machining period. It has been observed that tool wear varies significantly with the variation of cutting parameters. The analysis of variance (ANOVA) has been employed to analyze the influence of cutting parameters on tool wear in turning operation. Finally, the relationship between cutting parameters and the tool wear has been developed by using multiple regression analysis for each workpiece material.
Materials, 2022
The wear phenomenon of a dental milling cutter is studied based on experimental results and data and validated by statistical–mathematical modeling. The results of the statistical–mathematical modeling by the interpolation of the experimental results (data) regarding the wear of the dental milling cutter analyzed and obtained in the work process are presented in this paper. These results (data) are important because they lead to polynomial functions which by interpolation approximate very well the dependent parameter, specifically the wear process (mass lost due to dental milling cutter wear, mw), considered in the experimental program. The polynomial interpolation functions are valid, only during the experimental testing range of the dental milling cutter, to describe the wear phenomenon; the extrapolations do not lead to satisfactory results. However, by using a controlled interpolation function with an exponential component, the extrapolation of the results is possible. Therefore...
In this study, it is aimed to investigate the surface roughness of cutting tools during the machining of AISI 304 stainless steels, the life of cutting tools and the cutting forces that occur during cutting and machining. The main features of stainless steels are: high corrosion resistance, ductility and high tensile strength. Stainless steels contain elements such as chromium, nickel and molybdenum which affect the machinability in the negative direction; therefore it is very difficult to process stainless steels. This work was carried out using covered cutting tools. The work was carried out at different cutting depths and different feed rates without the use of cooling liquid. The life and wear mechanisms of cutting tools, cutting forces and surface roughness were investigated in relation to cutting parameters.