Machinability investigation with Wiper Ceramic Insert and Optimization during the Hard Turning of AISI 4340 Steel

Subbaiah, K. Venkata; Raju, Ch. Rama Bhadri; Pawade, Raju S.; Suresh, Ch.

doi:10.1016/j.matpr.2019.06.300

Cited by 16 publications

(10 citation statements)

References 14 publications

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“…As have, cryogenic cooling techniques [26], and special tools such as rotary tools (propelled or driven) [27]. It has been reported that wiper inserts, where the cutting edge is a series of radii rather than a single radius, as in conventional inserts, have been successful utilized for precision hard turning operations [28].…”

Section: Introductionmentioning

confidence: 99%

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

et al. 2020

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This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.

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Section: Introductionmentioning

confidence: 99%

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

et al. 2020

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“…Manufacturing cost is the chief remarkable feature to instigate the preamble of new technologies. The work material hardness has important statistical sways on the machined surface roughness, tooling wear and cutting force [93]. The Simulation effects propose that wiper tools can augment cutting force and peak cutting temperature as compared with the trial result; however, it can decrease the distribution temperature in the cutting tip that is valuable to decrease the tooling wear [94].…”

Section: Jena Et Al [29]mentioning

confidence: 99%

A Comprehensive Review on AISI 4340 Hardened Steel: Emphasis on Industry Implemented Machining Settings, Implications, and Statistical Analysis

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Turning of hardened AISI 4340 steel is regarded as one of the demanding challenges in machining sectors where precision tolerances are essential for automobile parts. The AISI 4340 steel is broadly utilized in forged steel automotive crankshafts systems, hydraulic forged and additional machine tool purposes because of their improved characteristics. Moreover, one of the keys confronts in the machining of hard 4340 steel is the comparatively deprived machining behavior that reduces the functionality of the material and further leads to component rejection at the final inspection stage. In addition, accelerated tool wear necessitates for repeated changing of cutting tool that results in higher machining and tooling costs. This comprehensive review aimed to present in-depth features on the development of machining performances using various cutting tools. This review focus is to provide a broad perceptive of the role of controllable variables during machining of hardened steel. This review analysis examines the response variables and their advantages of chip morphology and heat generation. The comprehensive overview of machining settings, key machinability indicators and statistical analysis for AISI 4340 steel. This overview will provide academic, industrial and scientific communities with benefits and shortcomings through improved conceptual understanding towards further research and development.

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“…Paiva et al [18] used principal component analysis and multivariate mean square error to find out Vc, DOC, and f that minimize five different surface components while turning AISI 52100 hardened steel using wiper inserts. Subbaiah et al [19] performed multi-objective optimization for turning AISI 4340 using wiper inserts. Desirability function with equal weights based on RSM was used to find out machining parameters (i.e., Vc, DOC, and f) which minimize surface roughness, cutting forces, and tool wear, while maximizing material removal rate.…”

Section: Introductionmentioning

confidence: 99%

Towards an Adaptive Design of Quality, Productivity and Economic Aspects When Machining AISI 4340 Steel With Wiper Inserts

et al. 2020

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The continuous pursue of sustainable manufacturing is motivating the utilization of new advanced technology, especially for hard to cut materials. In this study, an adaptive approach for optimization of machining process of AISI 4340 using wiper inserts is proposed. This approach is based on advance yet intuitive modeling and optimization techniques. The approach is based on Artificial Neural Network (ANN), Multi-Objective Genetic Algorithm (MOGA), as well as Linear Programming Techniques for Multidimensional Analysis of Preference (LINMAP), for modeling, optimization and multicriteria decision making respectively. This integrated approach, to best of the authors' knowledge, has been deployed for the first time to adaptively serve different designs of manufacturing processes. Such designs have different orientations, namely cost, quality, productivity, and balanced orientation. The capability of the proposed approach to serving such diverse requirements answers one of the most accelerating demands in the manufacturing community due to the dynamics of the uprising smart production lines. Besides, the proposed approach is presented in a straightforward manner that can be extended easily to other design orientations as well as other engineering applications. Based on the proposed design, a balanced general setting of 197.4 m/min, 0.95 mm, and 0.168 mm/rev was recommended along with other settings for more sophisticated requirements. Confirmatory experiments showed a good agreement (i.e., no more than 7% deviation) with the predicted optimum responses. This shows the validity of the proposed approach as a viable tool for designers to promote holistic and sustainable process design. INDEX TERMS Adaptive design, Artificial neural networks, Genetic Algorithm, Modeling, Wiper inserts, Turning, NOMENCLATURE ANN Artificial Neural Network B Balanced design DOC Depth of Cut EC Intensive cost-oriented design EP Intensive productivity-oriented design EQ Intensive quality-oriented design f Feed GRA Gray Relation Analysis IC Intensive cost-oriented design IP Intensive productivity-oriented design IQ Intensive quality-oriented design LINMAP

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Machinability investigation with Wiper Ceramic Insert and Optimization during the Hard Turning of AISI 4340 Steel

Cited by 16 publications

References 14 publications

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

A Comprehensive Review on AISI 4340 Hardened Steel: Emphasis on Industry Implemented Machining Settings, Implications, and Statistical Analysis

Towards an Adaptive Design of Quality, Productivity and Economic Aspects When Machining AISI 4340 Steel With Wiper Inserts

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