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Metals 2018, 8(4), 250; https://doi.org/10.3390/met8040250

Machinability of Eco-Friendly Lead-Free Brass Alloys: Cutting-Force and Surface-Roughness Optimization

1
ELKEME Hellenic Research Centre for Metals S.A., 56th km Athens—Lamia National Road, 32011 Oinofyta, Greece
2
Department of Materials Science and Engineering, University of Ioannina, 45110 Ioannina, Greece
3
Department of Mechanical Engineering, Technological Education Institute of Central Macedonia, 62124 Serres, Greece
*
Authors to whom correspondence should be addressed.
Received: 22 March 2018 / Revised: 3 April 2018 / Accepted: 4 April 2018 / Published: 8 April 2018
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Abstract

The machinability in turning mode of three lead-free brass alloys, CuZn42 (CW510L), CuZn38As (CW511L) and CuZn36 (C27450) was evaluated in comparison with a reference free-cutting leaded brass CuZn39Pb3 (CW614N), as far as the quality characteristics, i.e., cutting force and surface roughness, were concerned. A design of experiments (DOE) technique, according to the Taguchi L16 orthogonal array (OA) methodology, as well as analysis of variance (ANOVA) were employed in order to identify the critical-to-machinability parameters and to obtain their optimum values for high-performance machining. The experimental design consisted of four factors (cutting speed, depth of cut, feed rate and alloy) with four levels for each factor using the “smaller-the-better” criterion for quality characteristics’ optimization. The data means and signal-to-noise (S/N) responses indicated that the depth of cut and the feed rate were the most influential factors for the cutting force and surface roughness, respectively. The optimized machining parameters for cutting force (34.59 N) and surface roughness (1.22 μm) minimization were determined. Confirmation experiments (cutting force: 39.37 N and surface roughness: 1.71 μm) seem to show that they are in close agreement to the main conclusions, thereby validating the findings of the statistical evaluation performed. View Full-Text
Keywords: cutting force; surface roughness; lead-free brasses; turning; machinability; design of experiments (DOE) cutting force; surface roughness; lead-free brasses; turning; machinability; design of experiments (DOE)
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Toulfatzis, A.I.; Pantazopoulos, G.A.; David, C.N.; Sagris, D.S.; Paipetis, A.S. Machinability of Eco-Friendly Lead-Free Brass Alloys: Cutting-Force and Surface-Roughness Optimization. Metals 2018, 8, 250.

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