Performance comparison of wiper and conventional ceramic inserts in hard turning of AISI 4140 steel: analysis of machining forces and flank wear

Aouici, Hamdi; Elbah, M.; Yallese, Mohamed Athmane; Fnides, B.; Meddour, Ikhlas; Benlahmidi, S.

doi:10.1007/s00170-016-8567-7

Cited by 33 publications

(27 citation statements)

References 22 publications

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“…According to Table 4 , the level of agreement between the experimental and the numerical results for F main is high. Furthermore, based on the findings of Aouici et al [ 24 ] the experimental analysis of the machining components for the next indicative conditions: V c = 115 m/min, f = 0.11 mm/rev, and ap = 0.30 mm showed an increased correlation with the equivalent simulated results that were derived from the present study. That is, F r = 202.3 N, F t = 146.0 N, and F a = 86.6 N for the experiments and F r = 214.4 N, F t = 137.5 N, and F a = 77.4 N for the simulations, leading to an estimated relative error of 6.0%, −5.8%, and −10.6%, respectively.…”

Section: Resultssupporting

confidence: 75%

“…The numerical simulations were performed with the aid of DEFORM™-3D FEA software so that a FE model could be established. Moreover, a comparison between the experimental results found in the literature [ 24 ] and the numerical ones was conducted for validation purposes. Finally, after validating the FE model, a statistical model based on the response surface methodology (RSM) was developed.…”

Section: Introductionmentioning

confidence: 99%

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Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

et al. 2020

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The present study investigated the performance of three ceramic inserts in terms of the micro-geometry (nose radius and cutting edge type) with the aid of a 3D finite element (FE) model. A set of nine simulation runs was performed according to three levels of cutting speed and feed rate with respect to a predefined depth of cut and tool nose radius. The yielded results were compared to the experimental values that were acquired at identical cutting conditions as the simulated ones for verification purposes. Consequently, two more sets of nine simulations each were carried out so that a total of 27 turning simulation runs would adduce. The two extra sets corresponded to the same cutting conditions, but to different cutting tools (with varied nose radius). Moreover, a prediction model was established based on statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA), further investigating the relationship between the critical parameters (cutting speed, feed rate, and nose radius) and their influence on the generated turning force components. The comparison between the experimental values of the cutting force components and the simulated ones demonstrated an increased correlation that exceeded 89%. Similarly, the values derived from the statistical model were in compliance with the equivalent FE model values due to the verified adequacy.

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Section: Resultssupporting

confidence: 75%

Section: Introductionmentioning

confidence: 99%

Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

et al. 2020

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“…Because the verification of the generated models is a time-consuming process, the test setup was prepared according to widely-used parameters and settings. The selected cutting tool, material and cutting conditions, have already been successfully studied [30][31][32] and thus, were chosen for this study. The test framework is shown in Figure 7.…”

Section: Testing Of the Generated Cutting Tool Modelsmentioning

confidence: 99%

“…Table 3 contains the results of the nine numerical tests compared to the equivalent experimental ones. The experimental values were obtained from the literature [32]. The turning experiments were carried out with the aid of a universal lathe type SN 40C and the tool-holder with ISO designation number PCBNR2525M12.…”

Section: J Manuf Mater Process 2020 4 X For Peer Review 11 Of 15mentioning

confidence: 99%

CAD-Based Automated Design of FEA-Ready Cutting Tools

Tzotzis

García-Hernández

Talón

et al. 2020

JMMP

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The resources of modern Finite Element Analysis (FEA) software provide engineers with powerful mechanisms that can be used to investigate numerous machining processes with satisfying results. Nevertheless, the success of a simulation, especially in three dimensions, relies heavily on the accuracy of the cutting tool models that are implemented in the analyses. With this in mind, the present paper presents an application developed via Computer-Aided Design (CAD) programming that enables the automated design of accurate cutting tool models that can be used in 3D turning simulations. The presented application was developed with the aid of the programming resources of a commercially available CAD system. Moreover, the parametric design methodology was employed in order to design the tools according to the appropriate standards. Concluding, a sample tool model was tested by performing a number of machining simulations based on typical cutting parameters. The yielded results were then compared to experimental values of the generated machining force components for validation. The findings of the study prove the functionality of the tool models since a high level of agreement occurred between the acquired numerical results and the experimental ones.

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“…According to the authors [ 138 ], the physical measurements of the estimation with artificial neural network are appropriate. Aouici et al [ 139 ] compared the FW for the wiper ceramic insert with the traditional ceramic insert in dry hard turning of AISI 4140 steel. Analysis of variance was carried out in this study, and cutting speed, feed rate and depth of cut were also used as variables.…”

Section: Indirect Tool Condition Monitoring Systemsmentioning

confidence: 99%

A Review of Indirect Tool Condition Monitoring Systems and Decision-Making Methods in Turning: Critical Analysis and Trends

Kuntoğlu

Aslan

Pimenov

et al. 2020

Sensors

177

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The complex structure of turning aggravates obtaining the desired results in terms of tool wear and surface roughness. The existence of high temperature and pressure make difficult to reach and observe the cutting area. In-direct tool condition, monitoring systems provide tracking the condition of cutting tool via several released or converted energy types, namely, heat, acoustic emission, vibration, cutting forces and motor current. Tool wear inevitably progresses during metal cutting and has a relationship with these energy types. Indirect tool condition monitoring systems use sensors situated around the cutting area to state the wear condition of the cutting tool without intervention to cutting zone. In this study, sensors mostly used in indirect tool condition monitoring systems and their correlations between tool wear are reviewed to summarize the literature survey in this field for the last two decades. The reviews about tool condition monitoring systems in turning are very limited, and relationship between measured variables such as tool wear and vibration require a detailed analysis. In this work, the main aim is to discuss the effect of sensorial data on tool wear by considering previous published papers. As a computer aided electronic and mechanical support system, tool condition monitoring paves the way for machining industry and the future and development of Industry 4.0.

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Performance comparison of wiper and conventional ceramic inserts in hard turning of AISI 4140 steel: analysis of machining forces and flank wear

Cited by 33 publications

References 22 publications

Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

CAD-Based Automated Design of FEA-Ready Cutting Tools

A Review of Indirect Tool Condition Monitoring Systems and Decision-Making Methods in Turning: Critical Analysis and Trends

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