Comparative investigations of cryo-treated and untreated inserts on machinability of AISI 1050 by using response surface methodology, ANOVA and Taguchi design

Baday, Şehmus; Ersöz, Onur Alp

doi:10.1177/09544062211023117

Cited by 7 publications

(5 citation statements)

References 33 publications

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“…In general, workpiece surface roughness is highly dependent on feed. 28 It is also known that tool wear has a negative effect on surface roughness. In the experiments, as tool wear increased with each pass, the surface roughness of the workpiece became gradually worse.…”

Section: Resultsmentioning

confidence: 99%

“…The feed had the most prominent influence on surface roughness. 28 Although the feed is the main factor affecting surface roughness, it can be argued that other turning parameters also affected the results. In the literature, the effect of feed on surface roughness was determined to be 99.19% by Rashid et al, 20 68.5% by Subbaiah et al, 21 and 89.69% by Baday and Erso¨z.…”

Section: Surface Roughnessmentioning

confidence: 99%

“…In the literature, the effect of feed on surface roughness was determined to be 99.19% by Rashid et al, 20 68.5% by Subbaiah et al, 21 and 89.69% by Baday and Erso¨z. 28 A variable feed was used during the experiments, relying on different feed values, and different surface roughness values were obtained for each pass. Elba et al 12 proposed that when the feed increased by 75%, the surface roughness deteriorated by up to 66%.…”

Section: Surface Roughnessmentioning

confidence: 99%

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The analysis of the effect of varying feed values in each pass on tool wear and surface roughness in turning of AISI 4140

Sönmez

2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Machining is a complex process between the cutting tool and the workpiece, and in this process, the cutting tool constantly wears out with various wear mechanisms. Tool-wear estimation in turning is a complicated process; thus, there is a need for a study to reveal the time-dependent behavior of tool wear. In this study, tool wear and surface roughness change during the turning process of AISI 4140 steel at low cutting speeds were examined in detail with variable feed values for the first time. For this purpose, a half-minute cutting time was applied for each pass to analyze the tool wear as gradually as possible. Tool wear (flank, notch, and nose), surface roughness (Ra, Rz, and Rt), and chip morphologies were examined after each turning operation. The flank wear reached 0.3 mm, which is one of the tool life criteria according to ISO 3685, and the experiments were terminated at the 149th minute. Initially, a significant surface improvement (approx. 300%) was observed due to the decrease in feed values. In subsequent experiments, the effect of feed was significantly reduced due to increased tool wear, and limited surface roughness improvement (approx. 30%) was observed. At the beginning of the experiment, the chip breaker function of the cutting insert was successful at almost all feeds. However, in subsequent experiments, it was found that even at higher feeds, the chip breaker geometry of the insert deteriorated due to tool wear, causing changes in chip morphology, and resulting in long and undesirable chips.

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Section: Resultsmentioning

confidence: 99%

Section: Surface Roughnessmentioning

confidence: 99%

Section: Surface Roughnessmentioning

confidence: 99%

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The analysis of the effect of varying feed values in each pass on tool wear and surface roughness in turning of AISI 4140

Sönmez

2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…CT processes are generally applied to tool steels in two different ways: Shallow (-50°C to -100°C) and deep (-125°C to -196°C). Owing to the shallow and deep cryogenic processes (SC and DC) applied, improvements such as a reduction in the percentage of retained austenite and carbide volume and a more homogeneous distribution of carbides in the microstructure are provided [9][10][11][12][13][14][15][16][17]. As a result of all these important improvements in the microstructure, there is an increase in the important properties of tool steels such as wear resistance, hardness and tool life [15,[18][19][20].…”

Section: Introductionmentioning

confidence: 99%

Performances of cryo-treated and untreated cutting tools in machining of AA7075 aerospace aluminium alloy

Adin

2023

European Mechanical Science

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The quality of drilled holes in aluminium alloys used in the aerospace industry is vital to ensure high-precision structural integrity. For this reason, optimum selection of cost-effective cutting tools and cutting parameters is of great importance. Nowadays, due to their high cost and supply difficulties, there is a great interest in improving the performance of traditional HSS cutting tools as an alternative to ceramic, carbide and coated cutting tools. HSS cutting tools are widely used in different industries due to their cost-effectiveness and suitability to improve tool performance. In this research, the performances of cryo-treated (DC&T) and untreated (UT) HSS cutting tools used in dry machining of AA7075 aluminium alloys were investigated. Thanks to DC&T processes applied to HSS cutting tool, improvements have occurred in its microstructure. The hardness value of HSS cutting tool increased by 6.89% with the effect of DC&T processes applied. When the highest and lowest Ra values obtained using DC&T and UT HSS cutting tools were compared, it was seen that DC&T HSS cutting tool performed better by 11.05% and 25.91%, respectively. It has been determined that the hole surface quality of the aluminium workpiece machined with DC&T and UT HSS drills is negatively affected by the increase in spindle speed and feed rate. The highest S/N ratios calculated according to Ra values of holes drilled on aluminium workpieces using DC&T and UT HSS cutting tools were found to be -7.12 dB (2.27 μm) and -9.62 dB (3.03 μm), respectively. In the ANOVA analysis, it was determined that the most effective parameters on Ra values were spindle speed (70.62%), tools (18.19%) and feed rate (9.98%), respectively. In the regression analysis, R2 value for Ra values was calculated as 98.30%. High R2 value result shows that the model developed is quite successful in estimating Ra values.

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“…During machining, friction occurs between the tool and the workpiece [4]. Due to this friction, the cutting tool wears out over time [5]. Tool wear is inevitable, although it is possible to reduce tool wear by choosing the right machining conditions.…”

Section: Introductionmentioning

confidence: 99%

Machining of Hard-to-cut AISI 4462 Duplex Stainless Steel with an Environmentally Friendly Approach with Vortex Tube

Sönmez¹

2023

sv-jme

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Machining is a manufacturing process that can be used to produce precision machine parts and has many advantages. The first is the ability to achieve superior surface quality. Tool wear is an inevitable phenomenon that occurs during machining. It is affected by many machining conditions; therefore, this process needs to be monitored and controlled. In this study, tool wear and surface roughness tests were carried out on AISI 4462 duplex stainless-steel materials, known to be a hard-to-cut material. For this purpose, tool wear and surface roughness analyses were implemented by using the environmentally friendly vortex tube cooling system in addition to wet turning conditions for the first time. For both methods, experiments were conducted at a 1 mm depth of cut, 120 m/min cutting speed, and 0.1 mm/rev feed with a 90 mm cutting length for each pass. Both tool wear and surface roughness were examined at the end of each pass. The analysis showed that wet turning gave better results in terms of tool life (19.8 minutes of tool life) compared to 11.1 minutes of tool life in vortex turning. In contrast, the surface roughness values differed up to two times in some experiments, and the vortex tube experiments gave better surface roughness values in all passes. In addition, the vortex tube experiments showed less built-up-edge (BUE) formation than the wet-turning experiments.

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Comparative investigations of cryo-treated and untreated inserts on machinability of AISI 1050 by using response surface methodology, ANOVA and Taguchi design

Cited by 7 publications

References 33 publications

The analysis of the effect of varying feed values in each pass on tool wear and surface roughness in turning of AISI 4140

The analysis of the effect of varying feed values in each pass on tool wear and surface roughness in turning of AISI 4140

Performances of cryo-treated and untreated cutting tools in machining of AA7075 aerospace aluminium alloy

Machining of Hard-to-cut AISI 4462 Duplex Stainless Steel with an Environmentally Friendly Approach with Vortex Tube

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