Studying and Optimizing the Effect of Process Parameters on Machining Vibration in Turning Process of AISI 1040 Steel

Al-Shayea, Adel; Abdullah, Fawaz M.; Noman, Mohammed A.; Kaid, Husam; Nasr, Emad Abouel

doi:10.1155/2020/5480614

Cited by 13 publications

(5 citation statements)

References 40 publications

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“…In turning of AISI 1040 steel, the vibration increases as the a , v and f increase. 30 In cool conditions, the vibration value is the lowest in cutting number 2 (with cooling liquid). This is because the use of coolant reduces friction between the tool and the workpiece.…”

Section: Resultsmentioning

confidence: 97%

Investigation of machinability properties of AISI H11 tool steel for sustainable manufacturing

Şahinoğlu

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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In this experimental study, vibration, energy consumption, power consumption and surface roughness values that occur in the machining of AISI H11 tool steel under CO2, coolant and dry cutting conditions were investigated. The effects of different cutting parameters and cooling systems on machinability were investigated. Analysis of variance was done. Regression equations were obtained. Relationships between power consumption, vibration and surface roughness are explained with mathematical equations. Finally, the optimum CC were determined by the multiple optimization methods. According to the test results, while the instantaneous power consumption increases by increasing cutting parameters, energy consumption decreases as the processing time is shortened. Vibration value increases by increasing cutting parameters. The highest vibration value occurs in cutting with CO2. Compared to dry and CO2 cutting, the vibration is lowest in coolant cutting. The friction decreases with the coolant and the vibration value decreases. There is a similar relationship between vibration and surface roughness value. The most effective parameter on the surface roughness value is the feed rate. It was seen that the most suitable CC for the most efficient cutting, the lowest energy consumption, vibration and surface roughness value, under coolant cutting, 0.2 mm depth of cut, 175 m/min cutting speed and 0.119 mm/rev feed rate. With optimum CC, the vibration value was reduced by 5.18%, the surface roughness value by 37.12%, energy consumption by 36.19% and the machine efficiency was increased by 7.16%.

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Section: Resultsmentioning

confidence: 97%

Investigation of machinability properties of AISI H11 tool steel for sustainable manufacturing

Şahinoğlu

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…Tese experimental designs were developed using the Design-Expert v12 software, which is a tool that helps us in designing experiments and analyzing the data. To anticipate spindle and worktable vibration, a second-order mathematical equation was devised, whose appropriateness was determined using ANOVA [31,32]. Te MATLAB software was used for vibration optimization experiments.…”

Section: Experimental Designmentioning

confidence: 99%

A Hybrid Nondominant-Based Genetic Algorithm (NSGA-II) for Multiobjective Optimization to Minimize Vibration Amplitude in the End Milling Process

Gopal,

Gutema,

Lemu

et al. 2024

Advances in Materials Science and Engineering

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Aluminium is a noncorrosive, lightweight material used to fabricate parts for the aerospace, automobile, and construction industries. Due to the low-temperature resistance, more heat is generated. At the same time, in machining, tremendous efforts are taken to keep friction and chatter to a minimum and to attain better quality and perfect output, and also more attention is required while selecting the machining process parameters. Spindle speed, rate of feed, radial and axial depth of cut, and radial rake angle of the tool are the parameters utilized to machine aluminium 6063 using the HSS tool on CNC milling to estimate spindle and worktable vibration using a prediction model. In this study, the design of the experiment of the response surface methodology approach is used to create a second-order statistical equation for experimentation with the Design-Expert v12 software. The performance characteristics are analyzed using the ANOVA method. The spindle speed achieved the lowest vibration between 2000 and 3000 rpm. Next, axial and radial depths were the most vibration-affecting parameter compared to the rate of feed and radial rake angle of the tool. To find the best feasible response, the nondominant sorting genetic algorithm II (NSGA II) approach was trained and tested using MATLAB software. Using a Pareto-optimal technique, the optimum worktable vibration ranged from 0.00284 to 0.00165 mm/s2, whereas the spindle vibration ranged from 0.02404 to 0.01336 mm/s2. The predicted values were found to be in an excellent argument when Pareto-optimal solutions are used.

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“…In this context, 100 mm in diameter and 250 mm in length tempered steel samples were used. 1,[36][37][38][39][40] This steel material used extensively in most industry for a wide range of application such as; rotating machinery parts and components, crank shafts, motor shafts, axle shafts, pump shafts and railway locomotive traction motors shaft due to vibration behaviors. 1 The cutting tool of TNGA (TiN-Al 2 O 3 ) AB20 120408 T01020 and MTJNL 2525 M1604 model of tool holder were used in experimental study.…”

Section: Experiments Materials and Ceramic Cutting Toolmentioning

confidence: 99%

“…37 In an experimental study, it was investigated the effects of machining parameters in turning process of AISI 1040 steel. 38 In another study, it was studied the machining parameters and their effect on the Ra of steel samples machined under dry and wet turning conditions. Results revealed that, Ra is highly affected by the machining parameters and also the cooling conditions.…”

Section: Introductionmentioning

confidence: 99%

Analysis of tool vibration and surface roughness during turning process of tempered steel samples using Taguchi method

Kam

Demirtaş

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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This study analyzed the tool vibration (Vib) and surface roughness (Ra) during turning of AISI 4340 (34CrNiMo6) tempered steel samples using Taguchi Method. In this context, Taguchi design L18 (21 × 32) was used to analyze the experimental results. The vibration amplitude values from cutting tools were recorded for different machining parameters, control factors; two different sample hardness (46 and 53 HRc), three different cutting speeds (180, 220, 260 m.min−1), and feed rates (0.08, 0.14, 0.20 mm.rev−1) were selected. The machining parameters giving optimum Vib and Ra values were determined. Regression analysis is applied to predict values of Vib and Ra. Analysis of variance was used to determine the effects of machining parameters on the Vib and Ra values. The most important machining parameters were found to be the feed rate, sample hardness, and cutting speed for Vib and Ra, respectively. The lowest Vib and Ra values were obtained in 46 HRc sample as 0.0022 gRMS and 0.255 µm, respectively. The surface quality can be improved by reducing the sources of vibration by using appropriate machining parameters. As a result, there is a significant relationship between Ra and Vib. The lower Ra values were found during turning process of tempered steel samples according to the literature studies. It is suggested that the process can be preferred as an alternative process to grinding process due to lower cost and machining time. In application of the turning of experiment samples by ceramic cutting tool, a substantial technological and economical benefit has been observed.

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Studying and Optimizing the Effect of Process Parameters on Machining Vibration in Turning Process of AISI 1040 Steel

Cited by 13 publications

References 40 publications

Investigation of machinability properties of AISI H11 tool steel for sustainable manufacturing

Investigation of machinability properties of AISI H11 tool steel for sustainable manufacturing

A Hybrid Nondominant-Based Genetic Algorithm (NSGA-II) for Multiobjective Optimization to Minimize Vibration Amplitude in the End Milling Process

Analysis of tool vibration and surface roughness during turning process of tempered steel samples using Taguchi method

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