Modelling and Analysis of Surface Evolution on Turning of Hard-to-Cut CLARM 30NiCrMoV14 Steel Alloy
Abstract
:1. Introduction
2. Materials and Methods
2.1. Experimental Procedure
2.2. Experimental Design
3. Results and Discussion
3.1. Development of Mathematical Models
3.1.1. Comparison of Models
3.1.2. Lack of Fit Test
3.1.3. Model Summary Statistics
3.1.4. ANOVA for Surface Finish
3.2. Adequacy Measures and Model Validation
3.3. Response Surface Plots
3.3.1. Response Surface Plots for Rotational Speed and Feed
3.3.2. Response Surface Plots for Feed and Depth of Cut
3.3.3. Response Surface Plots for Depth of Cut and Speed
3.3.4. Analysis Based on Time
3.4. Confirmatory Trial Investigations
4. Conclusions
- From the investigation of the influence of the parameters on surface finish, it was revealed that feed rate is the most significant parameter, followed by the rotational speed. The increase in rotational speed at a low feed rate improves the surface finish, whereas, at a higher feed rate, the effect follows a slightly different trend, i.e., quality of surface finish is reduced, which is exhibited as a combined effect of feed, speed, and DOC.
- At low feed rates, the effect of DOC is not highly significant. However, at a higher feed rate, it greatly affects the tool wear. The combined effect of DOC and feed decreases the surface finish quality at higher values of input parameters. The sudden decrease in surface finish quality at low speeds has been measured with an increase in DOC. However, the same effect is less influenced at the same DOC with the increase in speed.
- Machining time, which was considered a categorical parameter in this research, also reduces the surface finish, though it is negligible at lower levels of time. This may be because of the tool wear observed as the machining time lapses.
- RSM has been successfully used in this research for the analysis of results and the development of mathematical models. The adequacy of the models was verified using standard statistical techniques and by applying the confirmatory experimental tests.
- The superior value of surface roughness obtained was 0.137 μm at parametric settings of 0.19 mm/rev feed, 90 rpm speed, 3 mm depth of cut, and 4 min time.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Element | Fe | C | Mn | Cr | Ni | Mo | V |
---|---|---|---|---|---|---|---|
% wt | 93.92 | 0.3 | 0.2 | 1.5 | 3.5 | 0.4 | 0.18 |
UTS (MPa) | 0.2% Ys (MPa) | % Elongation | Impact Strength (−40 °C) (J) |
---|---|---|---|
1300 | 1200 | 15 | 60 |
Parameters | Levels | ||||
---|---|---|---|---|---|
−2 | −1 | 0 | +1 | +2 | |
Feed (mm/rev) | 0.2 | 0.3 | 0.45 | 0.60 | 0.70 |
Speed (rpm) | 40 | 60 | 90 | 120 | 140 |
Depth of Cut (mm) | 1.32 | 2.00 | 3.00 | 4.00 | 4.68 |
Time (min) | - | 4 | 8 | 12 | - |
Source | Sum of Squares | DF | Mean Square | F Value | p-Value Prob > F | |
---|---|---|---|---|---|---|
Mean vs. Total | 643.86 | 1 | 643.86 | |||
Linear vs. Mean | 108.54 | 5 | 21.70 | 52.66 | <0.0001 | |
2FI vs. Linear | 12.788 | 9 | 1.42 | 7.91 | <0.0001 | |
Quadratic vs. 2FI | 4.877 | 3 | 1.62 | 27.60 | <0.0001 | Suggested |
Cubic vs. Quadratic | 1.41 | 16 | 0.08 | 2.50 | 0.0269 | Aliased |
Residual | 0.70 | 20 | 0.035 | |||
Total | 772.19 | 54 | 14.29 |
Source | Sum of Squares | DF | Mean Square | F-Value | p-Value | |
---|---|---|---|---|---|---|
Linear | 19.19178065 | 39 | 0.4921 | 7.448663 | 0.0016 | |
2FI | 6.403758775 | 30 | 0.21346 | 3.231033 | 0.0343 | |
Quadratic | 1.52597495 | 27 | 0.05652 | 0.855483 | 0.6471 | Suggested |
Cubic | 0.110821801 | 11 | 0.01007 | 0.152497 | 0.9975 | Aliased |
Pure Error | 0.59458625 | 9 | 0.06607 |
Source | Std. Deviation | R-Squared | Adjusted R-Squared | Predicted R-Squared | PRESS | |
---|---|---|---|---|---|---|
Linear | 0.6429 | 0.8458 | 0.8297 | 0.7995 | 25.72 | |
2FI | 0.4236 | 0.9454 | 0.9258 | 0.8998 | 12.85 | |
Quadratic | 0.2427 | 0.9834 | 0.9756 | 0.9615 | 4.92 | Suggested |
Cubic | 0.1878 | 0.9945 | 0.9854 | 0.9786 | 2.73 | Aliased |
Source | Sum of Squares | DF | Mean Square | F-Value | p-Value Prob > F | |
---|---|---|---|---|---|---|
Model | 125.60 | 9 | 13.95 | 225.51 | <0.0001 | Significant |
A—Feed | 102.83 | 1 | 102.83 | 1661.72 | <0.0001 | |
B—Speed | 0.5195 | 1 | 0.5195 | 8.39 | 0.0058 | |
C—Depth of cut | 2.60 | 1 | 2.60 | 42.06 | <0.0001 | |
D—Time | 2.57 | 2 | 1.28 | 20.84 | <0.0001 | |
AB | 6.49 | 1 | 6.49 | 104.96 | <0.0001 | |
AC | 1.42 | 1 | 1.42 | 23.05 | <0.0001 | |
BC | 4.36 | 1 | 4.36 | 70.54 | <0.0001 | |
A2 | 4.77 | 1.00 | 4.77 | 77.16 | <0.0001 | |
Residual | 2.72 | 44.00 | 0.062 | |||
Lack of Fit | 2.13 | 35.00 | 0.061 | 0.92 | 0.6029 | Not Significant |
Pure Error | 0.59 | 9.00 | 0.066 | |||
Cor Total | 128.32 | 53 |
Exp. Test | Feed | Speed | DOC | Time | Avg. Experimented | Predicted | Error % |
---|---|---|---|---|---|---|---|
1 | 0.5 | 75 | 2 | 4 | 3.563 | 3.417 | 4.3 |
2. | 0.6 | 60 | 3 | 12 | 4.599 | 4.453 | 3.3 |
3. | 0.4 | 80 | 2 | 8 | 2.737 | 2.834 | −3.4 |
4. | 0.65 | 110 | 3.5 | 8 | 5.787 | 5.657 | 2.3 |
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Raza, S.M.; Khan, A.M.; Farooq, M.U.; Iqbal, A.; Pimenov, D.Y.; Giasin, K.; Leksycki, K. Modelling and Analysis of Surface Evolution on Turning of Hard-to-Cut CLARM 30NiCrMoV14 Steel Alloy. Metals 2021, 11, 1751. https://doi.org/10.3390/met11111751
Raza SM, Khan AM, Farooq MU, Iqbal A, Pimenov DY, Giasin K, Leksycki K. Modelling and Analysis of Surface Evolution on Turning of Hard-to-Cut CLARM 30NiCrMoV14 Steel Alloy. Metals. 2021; 11(11):1751. https://doi.org/10.3390/met11111751
Chicago/Turabian StyleRaza, Syed Muhammad, Aqib Mashood Khan, Muhammad Umar Farooq, Asif Iqbal, Danil Yurievich Pimenov, Khaled Giasin, and Kamil Leksycki. 2021. "Modelling and Analysis of Surface Evolution on Turning of Hard-to-Cut CLARM 30NiCrMoV14 Steel Alloy" Metals 11, no. 11: 1751. https://doi.org/10.3390/met11111751