Comprehensive analysis of material removal rate, tool wear and surface roughness in electrical discharge turning of L2 tool steel

Çakıroğlu, Ramazan; Günay, Mustafa

doi:10.1016/j.jmrt.2020.04.060

Cited by 42 publications

(23 citation statements)

References 36 publications

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“…Accordingly, the levels of effectiveness of the parameters with various statistical values are expressed numerically. A large number of researchers employed statistical analysis to study the various machining parameters of a wide range of materials under different cutting conditions, which reflects the success of this approach [ 3 , 60 , 61 , 62 , 63 , 64 ].…”

Section: Introductionmentioning

confidence: 99%

Optimization and Analysis of Surface Roughness, Flank Wear and 5 Different Sensorial Data via Tool Condition Monitoring System in Turning of AISI 5140

Kuntoğlu

Aslan

Sağlam

et al. 2020

Sensors

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Optimization of tool life is required to tune the machining parameters and achieve the desired surface roughness of the machined components in a wide range of engineering applications. There are many machining input variables which can influence surface roughness and tool life during any machining process, such as cutting speed, feed rate and depth of cut. These parameters can be optimized to reduce surface roughness and increase tool life. The present study investigates the optimization of five different sensorial criteria, additional to tool wear (VB) and surface roughness (Ra), via the Tool Condition Monitoring System (TCMS) for the first time in the open literature. Based on the Taguchi L9 orthogonal design principle, the basic machining parameters cutting speed (vc), feed rate (f) and depth of cut (ap) were adopted for the turning of AISI 5140 steel. For this purpose, an optimization approach was used implementing five different sensors, namely dynamometer, vibration, AE (Acoustic Emission), temperature and motor current sensors, to a lathe. In this context, VB, Ra and sensorial data were evaluated to observe the effects of machining parameters. After that, an RSM (Response Surface Methodology)-based optimization approach was applied to the measured variables. Cutting force (97.8%) represented the most reliable sensor data, followed by the AE (95.7%), temperature (92.9%), vibration (81.3%) and current (74.6%) sensors, respectively. RSM provided the optimum cutting conditions (at vc = 150 m/min, f = 0.09 mm/rev, ap = 1 mm) to obtain the best results for VB, Ra and the sensorial data, with a high success rate (82.5%).

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Section: Introductionmentioning

confidence: 99%

Optimization and Analysis of Surface Roughness, Flank Wear and 5 Different Sensorial Data via Tool Condition Monitoring System in Turning of AISI 5140

Kuntoğlu

Aslan

Sağlam

et al. 2020

Sensors

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show abstract

“…Farklı işleme akımı, ark süresi ve bekleme süresinin kullanımında operasyon süreleri başta olmak üzere değişen yüzey pürüzlülüğü, kerf ölçüleri ve elektrot aşınma hızları tespit edilmiştir. [19]. Literatür çalışmaları göz önüne alındığında EEİ parametrelerinin yanı sıra işlem sırasında kullanılan dielektrik sıvı ve basıncının, elektrot malzemesinin mekanik ve kimyasal özelliklerinin de elektrot aşınmasına etki ettiği görülmektedir [9,16,20].…”

Section: Sonuç Ve Tartişma (Conclusion and Discussion)unclassified

The Effects of Cutting Parameters on the Kerf and Surface Roughness on the Electrode in Electro Erosion Process

Ceritbinmez¹,

Kanca

2021

Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım Ve Teknoloji

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During the electro erosion process, which is a thermal chip removal method, heating, melting and evaporation occur between the electrode material and the workpiece due to sparking and thermal effects, in this case both the workpiece and the electrode material are worn. In this study, the kerf angle and the electrode wear rate were analyzed by taking into account the size changes in the erosion areas of the copper electrode, which were eroded as a result of different processing parameters. a) b) Figure A. Kerf Angle Calculation (a) Longitudinal kerf measurement, b) Transverse kerf measurement)Purpose: In this study, electrode wear caused by machining from cold work tool steel with heat treated 60-62 HRC hardness was investigated by using electro erosion method and Cupro MAX CuCrZr electrode.In addition, it is aimed to determine the effects of processing parameters on the surface roughness of each electrode and electrode wear rates by going beyond the usual measurements.Theory and Methods: In this study,erosion process was performed using three different current values (6.25, 12.5, 25 A), three different pulse on times (3, 6, 9 µs) and pulse off times (4, 6, 8 µs), respectively, and the electrode wear rate of these processing parameters, the effects on kerf angle and surface roughness were analyzed by macro and analytical measurements.Surface roughness, kerf measurements and macro images of the electrodes were analyzed using Mitutoyo SJ200surface roughness tester, 0.001 mm precision mitutoyo micrometer and Nikon SMZ 745T microscope, respectively. ResultsThe results have shown that with increasing current, machining time decreased due to increased sparking between workpiece and electrode, but the average surface roughness, kerf angle and wear rate of the electrode increased.Theanalytical measurements and experimental results are presented and compared in Section 3. Conclusion:According to the analytical calculations and macro analysis results obtained as a result of experimental studies, it has been determined that as the pulse on time increases, the electrode wear rate decreases. The reduction in electrode wear resulted from the increase in the strength of the electrode due to the protective layer formed by the adhesion of the dielectric fluid and carbon particles released from the workpiece to the electrode surface. Highlights• Copper erosion.• EDM process.• Kerf measurement.

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“…In recent years, GRA has become one of the most preferred methods for multi-parameter/multiple parameter optimization [27][28][29][30].…”

Section: Materials and Experimental Proceduresmentioning

confidence: 99%

“…In the present study, the "smaller is better" approach was applied to minimize T, Fc and Ra simultaneously in the multiple response optimization process. First, the experimental results were normalized and the S/N values of the multiple response were obtained [27][28][29][30]. The values obtained as a result of the experiments and calculations are given in Table 4.…”

Section: Multiple Optimizationmentioning

confidence: 99%

The effects of cooling applications on tool life, surface quality, cutting forces, and cutting zone temperature in turning of Ni-based Inconel 625

Yağmur

2021

Int J Adv Manuf Technol

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Nickel-based super alloys are used in many elds, especially in the aviation and aerospace industries, due to their high temperature resistance. Besides these advantages, there are some machining di culties. Some cooling methods are used to minimize the machining di culties of these materials. For this purpose, in this study, tool life, tool wear (Vb), surface roughness (Ra), cutting forces (Fc) and cutting zone temperature (T) were investigated in turning Inconel 625 super alloys under different cooling conditions. Experiments were carried out under three different cutting conditions (Dry, minimum quantity lubrication (MQL) and Vortex cooling methods). Three feed rates (0.08, 0.1 and 0.12 mm/rev) and three cutting speeds 60, 80, 100 m/min) were used. Tool wear tests were carried out at average cutting speed and feed rate (80 m/min and 0,1 mm/rev). After the experiments, it was concluded that the cooling application affects positively in terms of tool life, cutting zone temperature and surface roughness.

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Comprehensive analysis of material removal rate, tool wear and surface roughness in electrical discharge turning of L2 tool steel

Cited by 42 publications

References 36 publications

Optimization and Analysis of Surface Roughness, Flank Wear and 5 Different Sensorial Data via Tool Condition Monitoring System in Turning of AISI 5140

Optimization and Analysis of Surface Roughness, Flank Wear and 5 Different Sensorial Data via Tool Condition Monitoring System in Turning of AISI 5140

The Effects of Cutting Parameters on the Kerf and Surface Roughness on the Electrode in Electro Erosion Process

The effects of cooling applications on tool life, surface quality, cutting forces, and cutting zone temperature in turning of Ni-based Inconel 625

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