An in-depth analysis of tool wear mechanisms and surface integrity during high-speed hard turning of AISI D2 steel via novel inserts

Khan, Sarmad Ali; Ameer, Muhammad Faizan; Uddin, Ghulam Moeen; Ali, Mohammad; Anwar, Saqib; Farooq, Muhammad Umar; Alfaify, Abdullah

doi:10.1007/s00170-022-10151-0

Cited by 16 publications

(4 citation statements)

References 40 publications

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“…Surface roughness decreases by 33.6% with an increasing value of spindle speed [ 49 , 50 ] from 6500 rpm to 7500 rpm, as higher spindle speed increases the machining temperature that softens the fibres of the workpiece and makes their cutting easy by leaving fewer ups and downs in the walls of the holes (as evident from Figure 9 ). A similar effect was observed by Ishida et al [ 51 ] during helical milling of CFRP stacks while working under different machining temperatures.…”

Section: Resultsmentioning

confidence: 99%

Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations on Process Performance and Hole Integrity

Mughal

Farooq

et al. 2023

Materials

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The structural components in the aeronautical industry require CFRP/Ti6Al4V stacks to be processed together, which results in poor hole integrity due to the thermal properties of the materials and challenges related to processability. These challenges include quality variation of the machined holes because of the limitations in process properties. Therefore, a novel solution through helical milling is investigated in the study using nano fluid based minimum quantity lubrication (NF-MQL). The analysis of variance shows, for Ti6Al4V, eccentricity (PCR = 28.56%), spindle speed (Ti) (PCR = 42.84%), and tangential feed (PCR = 8.61%), and for CFRP, tangential feed (PCR = 40.16%), spindle speed (PCR = 28.75%), and eccentricity (PCR = 8.41%) are the most significant parameters for diametric error. Further on, the rise in the circularity error is observed because of prolonged tool engagement at a higher value of tangential feed. Moreover, the surface roughness of Ti was reduced with an increasing percentage of MoS2 in the lubricant. The spindle speed (37.37%) and lubricant (45.76%) have a potential influence on the processing temperature, as evident in the analysis of variance. Similarly, spindle speed Ti (61.16%), tangential feed (23.37%), and lubrication (11.32%) controlled flank wear, which is critical to tool life. Moreover, the concentration of MoS2 decreased edge wear from ~105 µm (0.5% concentration) to ~70 µm (1% concentration). Thorough analyses on process performance in terms of hole accuracy, surface roughness, processing temperature, and tool wear are carried out based on the physical science of the process for cleaner production. The NF-MQL has significantly improved process performance and hole integrity.

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Section: Resultsmentioning

confidence: 99%

Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations on Process Performance and Hole Integrity

Mughal

Farooq

et al. 2023

Materials

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“…Therefore, more research is needed to contribute to stakeholders' knowledge on the workshop floor for decision-making and informed planning in machining AISI D2, owing to its importance and various application in manufacturing technology. Considering the contrary views of results, on which of process parameters (cutting speed, depth of cut, and feed rate) influences surface roughness most; as reported by [28,32,33], the feed rate is most significant compared to the depth of cut and cutting speed. Furthermore, [29] reported that cutting speed was the most significant factor, while [2] and [45] suggested depth of cut as most significant compared to feed rate and cutting speed.…”

Section: Introductionmentioning

confidence: 98%

“…The results show that the ML models provided better prediction accuracy and the optimization methodology reduced cost more than the traditional techniques with constant optimized cutting parameters. Khan et al [32] comprehensively analyzed surface integrity and tool wear during the hard turning of AISI D2 using novel prime inserts. It was reported that feed rate has a higher effect on the workpiece surface roughness than the depth of cut while cutting speed had an insignificant effect.…”

Section: Introductionmentioning

confidence: 99%

Surface Quality Prediction by Machine Learning Methods and Process Parameter Optimization in Ultra-Precision Machining of AISI D2 Using CBN tool

Adizue,

Tura,

Isaya

et al. 2023

Preprint

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High-quality machining is a crucial aspect of contemporary manufacturing technology due to the vast demand for precision machining for parts made from hardened tool steels and super alloys globally in the aerospace, automobile, and medical sectors. The necessity to upheave production efficiency and quality enhancement at minimum cost requires deep knowledge of this cutting process and development of machine learning-based modeling technique, adept in providing essential tools for design, planning, and incorporation in the machining processes. This research aims to develop a predictive surface roughness model and optimize its process parameters for Ultra-precision hard-turning finishing operation. Ultra-precision hard-turning experiments were carried out on AISI D2 of HRC 62. The response surface method (RSM) was applied to understand the effect of process parameters on surface roughness and carry out optimization. Based on the data gained from experiments, Machine learning models and algorithms were developed with Support vector machine (SVM), Gaussian process relation (GPR), Adaptive-neuro fuzzy inference system (ANFIS), and artificial neural network (ANN) for the prediction of surface roughness. The results show that ANFIS gave the best predictive accuracy of average R, RMSE, and MAPE values of 0.98, 0.06, and 9.98%, respectively, and that of additional validation tests were 0.81, 0.17 and 32.34%, respectively, which are found reasonably accurate. The RSM analysis shows that the feed is the most significant factor for minimizing surface roughness Ra among the process parameters, with 92% influence, and optimal cutting conditions was found to be cutting speed = 100 m/min, feed = 0.025 mm/rev and depth of cut = 0.09 mm, respectively. This finding can be helpful in the decision-making on process parameters in the precision machining industry.

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“…High-speed machining is an advanced technology that can produce high-precision products and reduce the costs associated with the assembly and storage of fixtures [1]. High-speed machining offers advantages such as fast metal removal rate leading to increased machining productivity, low cutting force, and good surface quality [2][3][4][5]. During high-speed machining, the chip moves out of the cutting zone faster, significantly reducing the cutting heat because the cutting heat is transferred mainly to the chip [6].…”

Section: Introductionmentioning

confidence: 99%

The Impact of High-Speed and Thermal-Assisted Machining on Tool Wear and Surface Roughness during Milling of SKD11 Steel

Mac

Luyen

Nguyen

2023

Metals

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This research investigates the impact of high-speed and thermal-assisted machining (HS-TAM) on tool wear and surface roughness during the milling of SKD11 steel. The goal is to identify high-speed and elevated temperature zones that can improve machining efficiency, enhance surface quality, minimize costs, and extend tool life. The study involves the high-speed milling of SKD11 steel at various temperature conditions to evaluate the effect of temperature on tool wear and surface roughness. Additionally, experiments are conducted at the highest allowable support temperature with increased high-speed cutting to examine the effect of high speed on tool wear and surface roughness. The study demonstrates the correlation between cutting-tool wear and surface roughness at various high-speed cutting conditions and TAM environments and provides recommendations for cutting speeds and heating temperatures for different quality and productivity objectives. The findings indicate that high-speed milling of SKD11 at 600 m/min and 500 °C can decrease cutting tool-wear height (wear volume) and surface roughness by 82.47% (95.74%) and 91.08%, respectively, compared to machining at room temperature. Furthermore, the higher-speed modes at 500 °C result in a slight increase in wear height and surface roughness for high-speed cutting below 800 m/min, but reduces surface roughness for high-speed cutting beyond 800 m/min, reaching a value of 0.158 µm at the high-speed cutting limit of 1000 m/min.

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An in-depth analysis of tool wear mechanisms and surface integrity during high-speed hard turning of AISI D2 steel via novel inserts

Cited by 16 publications

References 40 publications

Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations on Process Performance and Hole Integrity

Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations on Process Performance and Hole Integrity

Surface Quality Prediction by Machine Learning Methods and Process Parameter Optimization in Ultra-Precision Machining of AISI D2 Using CBN tool

The Impact of High-Speed and Thermal-Assisted Machining on Tool Wear and Surface Roughness during Milling of SKD11 Steel

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