Characterization and comparative machinability investigation of extruded and drawn copper alloys using non-parametric multi-response optimization and orthogonal arrays

Toulfatzis, Anagnostis; Besseris, George J.; Pantazopoulos, G.; Stergiou, Constantinos

doi:10.1007/s00170-011-3319-1

Cited by 24 publications

(31 citation statements)

References 27 publications

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“…A major factor contributing to the amelioration of machining efficiency was the alloy type, as has been also observed in other studies [8]. As should be noted, the schematic approach shown in Fig.…”

Section: Wh Work Hardening Index [%] Hv Final the Chip Average Hardnementioning

confidence: 61%

“…The optimal cutting parameters such as speed, feed and depth of cut as a multi-criterion plain turning problem were defined and experimentally confirmed, using a non-linear design of experiments approach [8][9][10]. The main objective of this study was to concurrently screen and optimize one quality and one process characteristic-chip morphology and power consumption-against the four controlling factors-speed, feed, depth of cut and alloy type-using multilevel Taguchi experimental designs and nonparametric data analysis.…”

Section: Introductionmentioning

confidence: 99%

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Machinability evaluation and screening of leaded and lead-free brasses using a non-linear robust multifactorial profiler

Toulfatzis

Pantazopoulos²,

Besseris

et al. 2016

Int J Adv Manuf Technol

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The aim of this work was the evaluation of the machinability of leaded brass namely CuZn39Pb3 (CW614N) in comparison to three lead-free brasses alloys namely CuZn42 (CW510L), CuZn38As (CW511L), and CuZn36 (C27450). The machinability of the studied alloys was investigated, based on chip morphology and power consumption, as quality characteristics. Microstructure examination and hardness testing was employed for the characterization of the selected alloys. Design of experiments (DOE) was employed in a multi-non-parametric study in order to identify the critical-to-machinability parameters and obtain their optimum values for high performance machining. The attempted joint screening using a four-level orthogonal array revealed that the depth of cut and the alloy type were the two statistically predominant effects. The chip morphology and the power consumption in a balanced concurrent optimization effort were optimal when the depth of cut was set at 0.5 mm for the alloy type CW614N chip morphology optimization. The optimal chip morphology response was split in equal chances to produce needle or arc chips. The predicted power consumption was confined in a range of values with an upper boundary at 65 W. The findings of the statistical evaluation were experimentally confirmed, validating the DOE approach. Keywords Machinable brass . Lead-free brasses . Machinability . Design of experiments (DOE) Nomenclature ANOVA Analysis of variance ER Error contribution HV final The chip average hardness (Vickers hardness) HV initial The initial surface hardness (Vickers hardness) MANOVA Multivariate analysis of variance M CM G Grand median value of CM data M P G Grand median value of P data mCM DC o Median value of CM for the optimal setting of DC effect mCM M o Median value of CM for the optimal setting of M effect mP DC o Median value of P for the optimal setting of DC effect mP M o Median value of P for the optimal setting of M effect MR Master response (ranked values of ssRS) OA Orthogonal array R 2 Coefficient of determination rCM i (i = 1,2) Ranked values of the response of the chip Morphology replicates rP i (i = 1,2) Ranked values of the response of the power consumption replicates srCM rSM 1 + rSM 2 srP rP 1 + rP 2 rCM Ranked values of srCM rP Ranked values of srP ssRS rCM 2 + rP 2 WH

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Section: Wh Work Hardening Index [%] Hv Final the Chip Average Hardnementioning

confidence: 61%

Section: Introductionmentioning

confidence: 99%

Machinability evaluation and screening of leaded and lead-free brasses using a non-linear robust multifactorial profiler

Toulfatzis

Pantazopoulos²,

Besseris

et al. 2016

Int J Adv Manuf Technol

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“…Machinability in these alloys is substantially improved by the presence and uniform distribution of fine size lead particles, since they serve as a chip-breaking constituent, impairing chip ductility and enhancing lubricity at the toolworkpiece interface [1,2]. Moreover, the presence of b-phase lowers the overall ductility of the alloy facilitating the segmentation of machining chips [1,4].…”

Section: Microstructurementioning

confidence: 99%

“…Moreover, the presence of b-phase lowers the overall ductility of the alloy facilitating the segmentation of machining chips [1,4]. b-phase also exhibits a characteristic plate-like morphology, which could be considered beneficial for chip-fracturing during machining, improving further machinability properties [2,4].…”

Section: Microstructurementioning

confidence: 99%

“…Improved machinability minimizes tool wear and allows for the production of high precision components, exhibiting superior surface finish. Machinability/microstructure relationships, together with some reference of the mechanical properties of leaded brass alloys, have been previously studied and presented in the relevant literature [1][2][3][4]. The evaluation of mechanical properties and the relevant fracture mechanisms of machinable brass rods is a valuable subject for investigation, as the mechanical performance of brass components impacts the reliability and safety of the entire system.…”

Section: Introductionmentioning

confidence: 99%

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Fracture Modes and Mechanical Characteristics of Machinable Brass Rods

Pantazopoulos¹,

Toulfatzis²

2012

Metallogr. Microstruct. Anal.

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Machinable brasses are a broad class of high strength copper-zinc alloys mainly containing lead to improve machinability. Conventional leaded brasses are widely used in several manufacturing sectors (i.e., fabrication of hydraulic components, fittings, valves, etc.) due to their superior workability in extrusion and drawing, together with their superior machinability for high efficiency production of final components in high speed/high precision machining centers. In addition to machinability, the mechanical behavior and general fracture mechanisms of these alloys are also important, due to their impact on the overall reliability and safety of brass components. In this study, the main fracture modes and mechanical characteristics of two industrial copper alloys, namely, CuZn39Pb3 and CuZn36Pb2As, are presented in relation to their microstructure. Optical metallography, macro-and microfractography, together with static and dynamic mechanical testing, were used as the principal analytical techniques for the present investigation.

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Effects of Temperature (In)homogeneity during Hot Stamping on Deformation Behavior, Structure, and Properties of Brass Valves

Kunčická

Kocich

2021

Adv Eng Mater

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Herein, assessing the effects of initial temperature (in)homogeneity on a hot‐stamped CuZn40Pb2 medical gas valve (fitting) via numerically and experimentally defining mutual relations of selected deformation parameters and optimizing temperature distribution within the original semi‐product heated via induction are focused. For these purposes, three preheating regimes are simulated, and deformation behaviors are evaluated. The predicted results are validated by experimental stamping and subsequent evaluation of the structure and properties of stamped fittings. The results show that preheating the semi‐product with a certain temperature gradient occurring between the axial and (sub)surface regions is favorable, as homogeneous initial temperature distribution results in rapid surface cooling by the effect of heat transfer from semi‐product to die, which imparts inhomogeneous stress distribution, local changes in structural phases, and possible occurrence of oxides. Too low (sub)surface temperature of the semi‐product can result in a significant (local) increase in flow stress, which consequently results in the danger of occurrence of forming defects. The brass fitting stamped with the optimized preheating procedure features an average grain size of 5.8 μm, uniform grains’ orientations with maximum texture intensity of two times random, and ultimate tensile strength of almost 400 MPa, while maintaining elongation to failure of more than 35%.

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Characterization and comparative machinability investigation of extruded and drawn copper alloys using non-parametric multi-response optimization and orthogonal arrays

Cited by 24 publications

References 27 publications

Machinability evaluation and screening of leaded and lead-free brasses using a non-linear robust multifactorial profiler

Machinability evaluation and screening of leaded and lead-free brasses using a non-linear robust multifactorial profiler

Fracture Modes and Mechanical Characteristics of Machinable Brass Rods

Effects of Temperature (In)homogeneity during Hot Stamping on Deformation Behavior, Structure, and Properties of Brass Valves

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