Cutting Force Model for Thermal-Assisted Machining of Tool Steel Based on the Taguchi Method

Abstract

This paper investigates cutting force in thermal-assisted machining (TAM) by induction heating for SKD11 tool steel which is widely used in the mold industry. Experimental studies were first conducted at room and elevated temperatures to evaluate the effectiveness of the heating process on chip morphology and the cutting forces during the thermal-assisted machining and comparing with conventional machining method. The Taguchi method based on orthogonal array and analysis of variance ANOVA method was then used to design the number of experiments and evaluate the influence of cutting speed, feed rate, cutting depth, and elevated temperature on the cutting force. Study results showed a decrease in the cutting force in the TAM process. The optimal condition of parameters obtained for thermal-assisted machining were cutting speed 280 m/min, feed rate 230 mm/min, cutting depth 0.5 mm and temperature 400 °C. Finally, a proposed equation was established to determine the cutting force that was presented as a function of elevated temperatures when milling SKD11 material. A proposed cutting force model was compared, evaluated and confirmed to be in good agreement with experimental results.

Optimization of Grinding Parameters for Minimum Grinding Time When Grinding Tablet Punches by CBN Wheel on CNC Milling Machine

“…After collecting results, the data were analyzed using ANOVA in Minitab 18 software. With the target function of the least grinding time, the criterion LB was selected for the S/N ratio, and it is described by the following equation [6][7][8][9][10][11][12][13][14]:…”

“…The impact of each parameter was determined by using S/N ratio, which helped to find the strength of experiments for the optimization of cutting parameters [9]. There exist three quality characteristics of the Taguchi technique known as the higher-the-better (HB), the lower-the-better (LB) and the nominal-the-best (NB) [6][7][8][9][10][11][12][13][14]. In this study, LB criterion was selected to be corresponding to the objective to achieve the least grinding time [6][7][8][9][10][11][12][13][14].…”

“…Then, the confirmation experiment was conducted to evaluate the appropriateness of the optimum parameters obtained from the Taguchi experimental design. This method allowed the analysis of the influence of cutting mode parameters on a selected response of the grinding process without a prohibitively high amount of experimentation and helped to determine optimal cutting parameters with a minimal number of experiments [6][7][8][9][10][11][12][13][14].…”

“…Regarding the above mentioned key factors, it is noticed that each factor changes three levels. Thus, the Taguchi design of the experiment was used to optimize the input parameters using an L9 (3 3 ) orthogonal array, presented in Table 3 [6][7][8][9][10][11][12][13][14]. Each experimental run was performed three times.…”

Assessment of the Effect of Thermal-Assisted Machining on the Machinability of SKD11 Alloy Steel

“…Although traditional techniques like diamond grinding or discharge machining are limited by high costs and specialized technologies, TAM has been introduced as an innovative solution to the challenges of machining SKD11. Studies have indicated that machining with TAM can reduce cutting forces by up to 40%, increase tool life, enhance surface roughness by up to 50%, and increase material removal rate when compared to machining at room temperature [11][12][13].…”