Multi-Response Optimization in High-Speed Machining of Ti-6Al-4V Using TOPSIS-Fuzzy Integrated Approach

Abbas, Adel T.; Sharma, Neeraj; Anwar, Saqib; Luqman, Monis; Tomaz, Ítalo; Hegab, Hussien

doi:10.3390/ma13051104

Cited by 29 publications

(19 citation statements)

References 25 publications

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“…Precision hard turning concerns the turning of material with superior mechanical properties [1], particularly high levels of strength [2] and hardness [3] such as alloy steels [4] and nickel-based super alloys [5,6], materials with high strength/weight ratio [7] and wear resistance [8] such as titanium alloys [9]. Although these materials fulfil a wide range of industrial requirements [10], they are difficult-to-cut and require advanced manufacturing processing techniques [11].…”

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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“…For aerospace components, machining is an important manufacturing process for superalloys such as titanium alloys, to achieve the required tight tolerances and complex geometries of the produced parts [ 6 ]. However, machining of titanium-based alloys has proved to be problematic and it is difficult to simultaneously attain more accurate components, lower machining costs, reduced material wastage, and higher rates of production [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

et al. 2020

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This article presents the results of an experimental investigation into the machinability of Ti6Al4V alloy during hard turning, including both conventional and high-speed machining, using polycrystalline diamond (PCD) inserts. A central composite design of experiment procedure was followed to examine the effects of variable process parameters; feed rate, cutting speed and depth of cut (each at five levels) and their interaction effects on surface roughness and cutting temperature as process responses. The results revealed that cutting temperature increased with increasing cutting speed and decreasing feed rate in both conventional and high-speed machining. It was found that high-speed machining showed an average increase in cutting temperature of 65% compared with conventional machining. Nevertheless, high-speed machining showed better performance in terms of lower surface roughness despite using higher feed rates compared to conventional machining. High-speed machining of Ti6Al4V showed an improvement in surface roughness of 11% compared with conventional machining, with a 207% increase in metal removal rate (MRR) which offered the opportunity to increase productivity. Finally, an inverse relationship was verified between generated cutting temperature and surface roughness. This was attributed mainly to the high cutting temperature generated, softening, and decreasing strength of the material in the vicinity of the cutting zone which in turn enabled smoother machining and reduced surface roughness.

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“…This is particularly important for finishing treatment. Abbas et al [17] observed that stabilization at the assumed level of the cutting force components allows to control the cutting tool deflection, which positively affects the quality of the machined surface. On the other hand, there are requirements for high machining efficiency in order to reduce production costs.…”

Section: Introductionmentioning

confidence: 99%

The Possibility of Applying Acoustic Emission and Dynamometric Methods for Monitoring the Turning Process

Dudzik

Labuda

2020

Materials

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Ensuring optimal turning conditions has a huge impact on the quality and properties of the machined surface. The condition of the cutting tool is one of the factors to achieve this goal. In order to control its wear during the turning process, monitoring was used. In this study, the acoustic emission method and measure of cutting forces during turning were used for monitoring that process. The research was carried out on a universal lathe center (CU500MRD type) using a Kistler dynamometer with assembled removable insert CCET09T302R-MF by DIJET Industrial CO., LTD. A dynamometer allows to measure forces Fx (radial force), Fy (feed force) and Fz (cutting force). The turning process was performed on a shaft with 60 mm diameter made of 304L stainless steel. The AE research was carried at Physical Acoustics Corporation with the kit that includes: recorder USB AE Node, preamplifier, AE-sensor VS 150M and computer with dedicated software used for recording and analyzing AE data. The aim of this paper is to compare selected diagnostic methods: acoustic emission and cutting forces measurement for monitoring wear of cutting tool edge. Analysis of the research results showed that both selected methods of monitoring the turning process allowed the determination of the beginning of the tool damage process.

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Multi-Response Optimization in High-Speed Machining of Ti-6Al-4V Using TOPSIS-Fuzzy Integrated Approach

Cited by 29 publications

References 25 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

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

The Possibility of Applying Acoustic Emission and Dynamometric Methods for Monitoring the Turning Process

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