Experimental investigation and performance analysis of cemented carbide inserts of different geometries using Taguchi based grey relational analysis

Senthilkumar, N.; Tamizharasan, T.; Anandakrishnan, V.

doi:10.1016/j.measurement.2014.09.025

Cited by 110 publications

(38 citation statements)

References 15 publications

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“…The model adequacy can be checked by incorporating verification of regression model, model coefficient, and lack of fit value (Senthilkumar, 2014). To satisfy all these purposes, ANOVA is the appropriate choice and the same has been applied in this study.…”

Section: Results and Analysismentioning

confidence: 99%

Modeling and optimization of surface roughness and tool vibration in CNC turning of Aluminum alloy using hybrid RSM-WPCA methodology

Sahoo¹,

Pratap²,

Bandyopadhyay³

2017

10.5267/j.ijiec

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This paper suggests an advanced hybrid multi output optimization technique by applying weighted principal component analysis (WPCA) incorporated with response surface methodology (RSM). This investigation has been carried out through a case study in CNC turning of Aluminum alloy 63400 for surface roughness (Ra) and tool vibration (db) optimization. Primarily, input parameters such as spindle speed (N), feed rate (S) and depth of cut (t) are designed for experiment by using RSM Box-Behnken methodology. The aluminum alloy workpieces are machined by using coated carbide tool (inserts) in dry environment. Secondly, the empirical model for the responses as the functions of cutting parameters are obtained through RSM technique and the adequacy of the models have been checked using analysis of variance (ANOVA). Finally, the process parameters are optimized using WPCA technique. The confirmatory experiment has been performed using optimized result and it reveals that multiple response performance index (MPI) value was increased by 0.2908 from initial setting. The increases in MPI value indicates that the aforesaid optimization methodology is suitably acceptable for multi response optimization for turning process.

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Section: Results and Analysismentioning

confidence: 99%

Modeling and optimization of surface roughness and tool vibration in CNC turning of Aluminum alloy using hybrid RSM-WPCA methodology

Sahoo¹,

Pratap²,

Bandyopadhyay³

2017

10.5267/j.ijiec

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“…Recently, Senthilkumar et al (2014) experimentally investigated the performance of cemented carbide inserts in terms of flank wear and surface roughness by assessing the effect of cutting parameters (v, f, d) and tool geometries (insert shape, relief angle and nose radius) and optimized using Taguchi based grey relational analysis in turning practically used automobile wheel axle materials of Ambassador car (512 BHN), Standard jeep (448 BHN), Ashok Leylank truck (522 BHN), based on the experiments designed using Taguchi's Design of Experiments (DoE). Analysis of variance shows that cutting insert shape is the prominent parameter followed by feed rate and depth of cut that contributes towards output responses.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert

Das

Panda

Dhupal

2017

Mech Adv Mater Mod Process

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Background: Now-a-days, newer hardened steel materials are coming rapidly into the market due to its wide applications in various fields of engineering. So the machinability investigation of these steel materials is one of the prime concern for practicing engineers, prior to actual machining. Methods: The present study addresses surface roughness, flank wear and chip morphology during dry hard turning of AISI 4340 steel (49 HRC) using CVD (TiN/TiCN/Al 2 O 3 /TiN) multilayer coated carbide tool. Three factors (cutting speed, feed and depth of cut) and three-level factorial experiment designs with Taguchi's L 9 Orthogonal array (OA) and statistical analysis of variance (ANOVA) were performed to investigate the consequent effect of these cutting parameters on the tool and workpiece in terms of flank wear and surface roughness. For better understanding of the cutting process, surface topography of machined workpieces, wear mechanisms of worn coated carbide tool and chip morphology of generated chips were observed by scanning electron microscope (SEM). Consequently, multiple regression analysis was adopted to develop mathematical model for each response, along with various diagnostic tests were performed to check the validity and efficacy of the proposed model. Finally, to justify the economical feasibility of coated carbide tool in hard turning application, a cost analysis was performed based on Gilbert's approach by evaluating the tool life under optimized cutting condition (suggested by response optimization technique).

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“…Because surface roughness affects several functional attributes such as corrosion resistance, tribological characteristics, fatigue strength, and wear resistance of machined components, various researchers have employed methods which includes experimental, statistical, and analytical approaches in hard turning operation with various workpiece materials [18CrMo4, 42CrMo4, SEA8620, AISI 1040, 1045 for modeling and optimization using response surface methodology (RSM) (Elbah et al 2013;Hessainia et al 2013;Shihab et al 2014;Azam et al 2015;Meddour et al 2015;Bouzid et al 2015), Taguchi method (Gunay and Yucel 2013;Rashid et al 2016;Zerti et al 2016;Panda et al 2016;Das et al 2017a), ANN (Asiltürk and Çunkaş 2011;Pontes et al 2012;Asiltürk 2012;Mia and Dhar 2016), GRA (Sahoo and Sahoo 2013a;Kacal and Yildirim 2012;Senthilkumar et al 2014), GA (Batish et al 2014;Bouacha and Terrab 2016), and particle swarm optimization (PSO) (Stryczek and Pytlak 2014;Yue et al 2016) to attain the surface quality and dimensional finishing condition similar to costly cylindrical grinding. For example, Hessainia et al (2015) found that response surface methodology represents a powerful approach and can offer to scientific researchers as well industrial metal workers a helpful optimization procedure for various combinations of the workpiece and the cut material tool.…”

Section: Introductionmentioning

confidence: 99%

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Panda

Das

Dhupal

2017

Process Integr Optim Sustain

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The paper addresses the assessment, modeling, and optimization study of surface roughness in finish dry hard turning (FDHT) of AISI 4340 steel with coated ceramic tool by considering the cutting speed, axial feed, depth of cut, and nose radius as machining parameters. Thirty sets of longitudinal turning trials based on central composite (CCD) design of experiments (DOEs) are performed, and response surface methodology (RSM), particle swarm optimization (PSO), and finally, Gilbert's approach are subsequently applied for mathematical modeling, response optimization, tool life estimation, and economic analysis. Additionally, various diagnostic tests have been executed to check the statistical significance and validity, adequacy, effectiveness, and fitness of data of the proposed model using analysis of variance (ANOVA) and Anderson-Darling normal probability test. Results indicated that nose radius and feed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness is considered. The RSM model combined with PSO technique leads to minimum surface roughness value similar to cylindrical grinding of 0.2021 μm, corresponding to optimum process parameters: 220 m/min of cutting speed, 0.05 mm/rev of feed, 0.193 mm of depth of cut, and 1.6 mm of tool nose radius. Finally, under pre-cited optimum machining conditions, tool life was evaluated to perform cost analysis for the economical justification and feasibility of coated ceramic tools in hard turning. The total machining cost per piece is ensued to be lower ($0.34) as a consequence of higher tool life (44 min), reduction in downtime, and enhancement in savings, which finds economical benefits in hard turning. The novelty aspects of the present work are that (i) it demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing coated ceramic tool in hard turning processes considering technological, economical, and ecological aspects, which are helpful and efficient from industrial point of view and (ii) it contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-55 HRC.

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Experimental investigation and performance analysis of cemented carbide inserts of different geometries using Taguchi based grey relational analysis

Cited by 110 publications

References 15 publications

Modeling and optimization of surface roughness and tool vibration in CNC turning of Aluminum alloy using hybrid RSM-WPCA methodology

Modeling and optimization of surface roughness and tool vibration in CNC turning of Aluminum alloy using hybrid RSM-WPCA methodology

Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

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