Application of response surface methodology for determining cutting force model in turning hardened AISI H11 hot work tool steel

Fnides, B.; Yallese, Mohamed Athmane; Mabrouki, Tarek; Rigal, Jean-François

doi:10.1007/s12046-011-0007-7

Cited by 57 publications

(46 citation statements)

References 13 publications

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“…Respectively, their contributions are 0.07% and 0.09%. These results are close to those found in [13][14][15][16][17][18][19][20][21]. The difference is the hardness of machined steel, its chemical composition and its mechanical characteristics.…”

Section: Anova For F a F R And F Tsupporting

confidence: 89%

Analysis of technological parameters through response surface methodology in machining hardened X38CrMoV5-1 using whisker ceramic tool (Al2O3+SiC)

Fnides¹,

Berkani²,

Yallese³

et al. 2012

Estonian J. Eng.

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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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Section: Anova For F a F R And F Tsupporting

confidence: 89%

Analysis of technological parameters through response surface methodology in machining hardened X38CrMoV5-1 using whisker ceramic tool (Al2O3+SiC)

Fnides¹,

Berkani²,

Yallese³

et al. 2012

Estonian J. Eng.

Self Cite

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show abstract

“…Compared to grinding operations, precision hard turning enabled relatively high material removal rate and flexibility and thus, became more attractive especially to automotive, bearing and hydraulic industries [1][2][3]. Huang et al presented a thorough review that discusses CBN tool material microstructure, encountered wear patterns and tool wear rate modeling under hard turning [4].…”

Section: Introductionmentioning

confidence: 99%

Modeling and optimization of hard turning of X38CrMoV5-1 steel with CBN tool: Machining parameters effects on flank wear and surface roughness

et al. 2011

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The present study, aims to investigate, under turning conditions of hardened AISI H11 (X38CrMoV5-1), the effects of cutting parameters on flank wear (VB) and surface roughness (Ra) using CBN tool. 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), are explored employing the analysis of variance (ANOVA). Optimal cutting conditions for each performance level are established and the relationship between the variables and the technological parameters is determined using a quadratic regression model. The results show that the flank wear is influenced principally by the cutting time and in the second level by the cutting speed. Also, it is that indicated that the feed rate is the dominant factor affecting workpiece surface roughness.

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“…Arsecularatne et al [18] and Ding et al [19] chose an orthogonal test (OT) to study the effect of cutting parameters on cutting force, and demonstrated suitable cutting force models. Lalwani et al [20] and Fnides et al [21] used the RSM to study effects of various parameters on the cutting force and provided their prediction accordingly. These methods have distinct differences in their numbers of tests used: RSM used more experimental data than OT.…”

Section: The Second Cutting Stepmentioning

confidence: 99%

Cutting force models for Fe–Al-based coating processed by a compound NC machine tool

Sun

Zhang

Zhang³

et al. 2015

Int J Adv Manuf Technol

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The arc-spraying Fe-Al-based coating cutting process is a spindle-tool-workpiece vibration system dependent upon the machine tool's dynamic performance, cutting tool vibration, the coarse coating surface and its thin cutting depth. To investigate the cutting force, this research indicates the coating cutting fundamental mechanics; furthermore, it represents two cutting steps and cutting force models in the machining process avoiding an analysis of the natural vibration parameters of the machine tool itself. In the first cutting step, there is a transient cutting force due to forced vibration of the rough surface; the second cutting step has a steady machining feature based on the first cutting surface and the reduced hardness of the inhomogeneous region. According to the different characteristics of each cutting step, this research presents dynamic cutting calculation models including cutting parameters, tool vibration and cutting depth effects in the first cutting step. A steady cutting model is based on three cutting parameters including cutting velocity, cutting feed and cutting depth. Piezoelectric force and acceleration sensors were used to obtain accurate experimental data. Then, response surface methodology (RSM) and the principle of least squares estimation of polynomial regression (PLSEPR) were applied to analyse the resultant cutting data. The results showed that cutting force calculation models were suitable for the coating machining.

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Application of response surface methodology for determining cutting force model in turning hardened AISI H11 hot work tool steel

Cited by 57 publications

References 13 publications

Analysis of technological parameters through response surface methodology in machining hardened X38CrMoV5-1 using whisker ceramic tool (Al2O3+SiC)

Analysis of technological parameters through response surface methodology in machining hardened X38CrMoV5-1 using whisker ceramic tool (Al2O3+SiC)

Modeling and optimization of hard turning of X38CrMoV5-1 steel with CBN tool: Machining parameters effects on flank wear and surface roughness

Cutting force models for Fe–Al-based coating processed by a compound NC machine tool

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