International audienceThe objective of this article is to manufacture low-cost, high-quality products with maximum productivity in short time. In this work, four stages are considered: statistical investigation of the experimental results based on ANOVA, modelling based on regression analysis and mono- and multi-objective optimizations. In the first stage, turning experiments were carried out using an orthogonal array (L16) of Taguchi. Effects of cutting parameters on surface roughness and material removal rate were determined using ANOVA and interaction plots. In the second stage, regression analysis was utilized to formulate second-order models of all data gathered in the experimental works; these models could be used to predict responses in turning of X20Cr13 steel with a minor error. In the third stage, responses were used alone in an optimization study as an objective function. To minimize all responses, Taguchi’s signal-to-noise ratio was used. In the fourth stage, responses were optimized simultaneously using grey relational analysis
This paper presents a comparison of surface roughness between both ceramic cutting tools namely, TiN coated mixed ceramic CC6050 and uncoated mixed ceramic CC650 when machining hardened hot work steel X38CrMoV5-1 [AISI H11] treated at 50 HRC. A mathematical model, relating surface roughness criteria and main factors such as cutting radius, cutting speed, feed rate, and depth of cut, was developed using response surface methodology (RSM) and its adequacy was checked by regression analysis. The effect of cutting parameters on surface roughness is evaluated and the optimum cutting conditions to minimize the surface roughness are determined. A multiple linear models have been established between the cutting parameters and the surface roughness using response surface methodology. The experimental results reveal that the most significant machining parameter for surface roughness is the feed followed by cutting radius. Also the determined optimal conditions really reduce the surface roughness on the machining of AISI H11 steels within the ranges of parameters studied. In addition, excellent surface roughness was obtained in hard turning using CC650 tools. The coated ceramic tools had no advantage over CC650 from the point of view of surface roughness. Keywords Hard turning . AISI H11 steel . Ceramic . Surface roughness . ANOVA . RSM Nomenclature Vc Cutting speed (m/min) HRC Rockwell hardness f Feed rate (mm/rev) ANOVA Analysis of variance ap Depth of cut (mm) RSM Response surface methodology r Cutting radius (mm) DF Degrees of freedom Ra Arithmetic mean roughness (μm) Seq SS Sequential sum of squares Rt Total roughness (μm) Adj MS Adjusted mean squares Fc Tangential force (N) Cont. % Contribution ratio (%) HT Hard turning R² Coefficient of determination (%).
The aim of this experimental study is to evaluate the tool life of each cutting material used in dry hard turning of AISI Hll, treated at 50 HRC. This steel is intended for hot work, is free from tungsten on CrMoV basis, insensitive to temperature changes and has a high wear resistance. It is employed for the manufacture of the moulds and inserts, module matrices of car doors and helicopter rotor blades. The tests of straight turning were carried out using the following cutting materials: carbides (H13A and GC3015), ceramics (mixed CC650 and reinforced CC670) and cermets (CT5015 and GC1525). Experimental results enable us to study the influence of machining time on flank wear VB of these cutting materials and to determine their lifespan for this cutting regime (depth of cut a^ = 0.15 mm, feed rate/= 0.08 mm/rev and cutting speed K^ = 120 m/min). It arises that mixed ceramic (insert CC650) is more resistant to wear than cutting materials. Its tool life is 49 min and consequently, it is the most powerful.
This experimental study is an attempt to model technological parameters such as cutting forces and surface roughness in hard turning of X38CrMoV5-1 hot work tool steel hardened to 50 HRC. This steel is free from tungsten on Cr-Mo-V basis, insensitive to temperature changes and has a high wear resistance. It is employed for the manufacture of helicopter rotor blades and forging dies. The workpiece is machined by a whisker ceramic tool (insert CC670 of chemical composition 75%Al 2 O 3 +25%SiC) under dry conditions. Based on 3 3 full factorial design, a total of 27 tests are carried out. The range of each parameter is set at three different levels, namely low, medium and high. Mathematical models were deduced by applying analysis of variance (ANOVA) and through factor interaction graphs in the response surface methodology (RSM) in order to express the influence degree of each cutting regime element on cutting force components and surface roughness criteria. The results indicate that the depth of cut is the dominant factor affecting cutting force components. The feed rate influences tangential cutting force more than radial and axial forces. The cutting speed affects radial force more than tangential and axial forces. The results also reveal that feed rate is the dominant factor affecting surface roughness, followed by cutting speed. As for the depth of cut, its effect is not very important. These mathematical models would be helpful in selecting cutting variables for optimization of hard cutting process.
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