Machining of Inserts with PCD Cutting-Edge Technology and Determination of Optimum Machining Conditions Based on Roundness Deviation and Chip-Cross Section of AW 5083 AL-Alloy Verified with Grey Relation Analysis
Abstract
:1. Introduction
2. Experimental Conditions and Procedure
3. Manufacturing Process of PCD Cutting Inserts
3.1. Sharpening Process
3.2. Optimalization of Input Factors for AW 5083 Processing
- Identify the input factors and the parameters for evaluating the output quality and performance of the cutting process;
- Determination of the number of levels for the input factors of the cutting process;
- Design of the factorial matrix of the experiment and assignment of the factors of the cutting process;
- Results of experiments for roundness deviation and chip cross-section;
- GRG generation and calculation of GRC coefficients;
- Calculation of GRGrades based on GRC results;
- Analysis of experimental results with GRGrade;
- Design of optimum levels of cutting process parameters.
3.3. Data Pre-Processing
3.4. Confirmation Test
4. Discussion
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Factor Level | A Cutting Speed (m/min) | B Feed Rate (mm/rev) | C Depth of Cut (mm) | D Corner Radius (mm) |
---|---|---|---|---|
Lower (−1) | 450 | 0.1 | 0.1 | 0.4 |
Medium (0) | 660 | 0.2 | 0.3 | 0.8 |
Upper (+1) | 870 | 0.3 | 0.5 | 1.2 |
Basic Properties of PVD-VTB 010 Material | PCD-CTB 010 |
---|---|
Grain size | 10 μm |
Density | 4.08 g/ |
Binder | Cobalt |
Thermal Conductivity | 501 W/m·K |
Thermal Diffusion | 0.27 × 10−3 /s |
Cobalt Content | 10.3% |
Diamond Share | 89.7% |
Al Alloy | % |
---|---|
Si | 0.40 |
Fe | 0.4 |
Cu | 0.10 |
Mn | 0.4–0.10 |
Mg | 4.0–4.9 |
Cr | 0.05–0.25 |
Zn | 0.25 |
Ti | 0.15 |
Others. | 0.35 |
Al | balance |
Al Alloy | Value |
---|---|
Yield stress Rp 0.2 (MPa) | 110 |
Tensile strength Rm (MPa) | 270 |
Density [kg/m3] | 2660 |
Melting range [°C] | 575–683 |
Electrical Conductivity (MS/m) | 16–19 |
Thermal Conductivity (W/m·K) | 110–140 |
Modulus of Elasticity (GPa) | 70 |
Number | A | B | C | D | Δd | Sch |
---|---|---|---|---|---|---|
of Experiment | (mm) | (mm2) | ||||
1 | −1 | −1 | −1 | −1 | 0.0112 | 0.2194 |
2 | −1 | −1 | −1 | 1 | 0.0106 | 0.2082 |
3 | −1 | −1 | 1 | −1 | 0.0124 | 0.2193 |
4 | −1 | −1 | 1 | 1 | 0.0114 | 0.2105 |
5 | −1 | 1 | −1 | −1 | 0.0131 | 0.2088 |
6 | −1 | 1 | −1 | 1 | 0.0106 | 0.3841 |
7 | −1 | 1 | 1 | −1 | 0.0142 | 0.2238 |
8 | 1 | 1 | 1 | 1 | 0.0124 | 0.3917 |
9 | 1 | −1 | −1 | −1 | 0.0116 | 0.2345 |
10 | 1 | −1 | −1 | 1 | 0.0108 | 0.2453 |
11 | 1 | −1 | 1 | −1 | 0.0104 | 0.2153 |
12 | 1 | −1 | 1 | 1 | 0.0102 | 0.2316 |
13 | 1 | 1 | −1 | −1 | 0.0147 | 0.2162 |
14 | 1 | 1 | −1 | 1 | 0.0115 | 0.2644 |
15 | 1 | 1 | 1 | −1 | 0.0117 | 0.2592 |
16 | 1 | 1 | 1 | 1 | 0.0103 | 0.2458 |
17 | 0 | 0 | 0 | 0 | 0.0126 | 0.2652 |
18 | 0 | 0 | 0 | 0 | 0.0117 | 0.2388 |
19 | 0 | 0 | 0 | 0 | 0.0104 | 0.3943 |
20 | 0 | 0 | 0 | 0 | 0.0119 | 0.2715 |
21 | 0 | 0 | 0 | 0 | 0.0128 | 0.2225 |
22 | 0 | 0 | 0 | 0 | 0.0106 | 0.2263 |
23 | 0 | 0 | 0 | 0 | 0.0105 | 0.2844 |
24 | 0 | 0 | 0 | 0 | 0.0129 | 0.2135 |
Reference Comparability Sequence | Δd (mm) | Sch (mm2) |
---|---|---|
Reference sequence comparability sequence | 1.000 | 1.000 |
E1 | 0.778 | 0.940 |
E2 | 0.911 | 1.000 |
E3 | 0.511 | 0.940 |
E4 | 0.733 | 0.988 |
E5 | 0.356 | 0.997 |
E6 | 0.911 | 0.055 |
E7 | 0.111 | 0.916 |
E8 | 0.511 | 0.014 |
E9 | 0.689 | 0.859 |
E10 | 0.867 | 0.801 |
E11 | 0.956 | 0.962 |
E12 | 1.000 | 0.874 |
E13 | 0.000 | 0.957 |
E14 | 0.711 | 0.698 |
E15 | 0.667 | 0.726 |
E16 | 0.978 | 0.798 |
E17 | 0.467 | 0.694 |
E18 | 0.667 | 0.836 |
E19 | 0.956 | 0.000 |
E20 | 0.622 | 0.660 |
E21 | 0.422 | 0.923 |
E22 | 0.911 | 0.903 |
E23 | 0.933 | 0.591 |
E24 | 0.400 | 0.972 |
Deviation Sequence | Δoi (Δd) | Δoi (Sch) |
---|---|---|
E1 | 0.222 | 0.060 |
E2 | 0.089 | 0.000 |
E3 | 0.489 | 0.060 |
E4 | 0.267 | 0.012 |
E5 | 0.644 | 0.003 |
E6 | 0.089 | 0.945 |
E7 | 0.889 | 0.084 |
E8 | 0.489 | 0.968 |
E9 | 0.311 | 0.141 |
E10 | 0.133 | 0.199 |
E11 | 0.044 | 0.038 |
E12 | 0.000 | 0.126 |
E13 | 1.000 | 0.043 |
E14 | 0.289 | 0.302 |
E15 | 0.333 | 0.274 |
E16 | 0.022 | 0.202 |
E17 | 0.533 | 0.306 |
E18 | 0.333 | 0.164 |
E19 | 0.044 | 1.000 |
E20 | 0.378 | 0.340 |
E21 | 0.578 | 0.077 |
E22 | 0.089 | 0.097 |
E23 | 0.067 | 0.409 |
E24 | 0.600 | 0.028 |
Number of Experiment | GRC (Δd) | GRC (Sch) | GRG |
---|---|---|---|
E1 | 0.692 | 0.893 | 0.792 |
E2 | 0.849 | 1.000 | 0.925 |
E3 | 0.506 | 0.893 | 0.700 |
E4 | 0.652 | 0.976 | 0.814 |
E5 | 0.437 | 0.994 | 0.715 |
E6 | 0.849 | 0.346 | 0.598 |
E7 | 0.360 | 0.856 | 0.608 |
E8 | 0.506 | 0.336 | 0.421 |
E9 | 0.616 | 0.780 | 0.698 |
E10 | 0.789 | 0.715 | 0.752 |
E11 | 0.918 | 0.929 | 0.924 |
E12 | 1.000 | 0.799 | 0.900 |
E13 | 0.333 | 0.921 | 0.627 |
E14 | 0.634 | 0.623 | 0.629 |
E15 | 0.600 | 0.646 | 0.623 |
E16 | 0.957 | 0.712 | 0.835 |
E17 | 0.484 | 0.620 | 0.552 |
E18 | 0.600 | 0.753 | 0.676 |
E19 | 0.918 | 0.333 | 0.626 |
E20 | 0.570 | 0.595 | 0.582 |
E21 | 0.464 | 0.867 | 0.665 |
E22 | 0.849 | 0.837 | 0.843 |
E23 | 0.882 | 0.550 | 0.716 |
E24 | 0.455 | 0.946 | 0.700 |
−1 | 0 | 1 | Max-Min | |
---|---|---|---|---|
A | 0.697 | 0.670 | 0.749 | 0.079 |
B | 0.813 | 0.670 | 0.632 | 0.181 |
C | 0.717 | 0.670 | 0.728 | 0.058 |
D | 0.717 | 0.670 | 0.734 | 0.064 |
Name of Experiment | Factor Combination | Deviation of Roundness (mm) | Chip Cross-Section (mm2) |
---|---|---|---|
Initial plan | A2.B2.C2.D2 | 0.0117 | 0.2646 |
Optimal plan | A3.B1.C3.D3 | 0.0102 | 0.2316 |
The result of finding the optimal combination of parameters | 12.83% | 12.48% |
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Miškiv-Pavlík, M.; Jurko, J. Machining of Inserts with PCD Cutting-Edge Technology and Determination of Optimum Machining Conditions Based on Roundness Deviation and Chip-Cross Section of AW 5083 AL-Alloy Verified with Grey Relation Analysis. Processes 2021, 9, 1485. https://doi.org/10.3390/pr9091485
Miškiv-Pavlík M, Jurko J. Machining of Inserts with PCD Cutting-Edge Technology and Determination of Optimum Machining Conditions Based on Roundness Deviation and Chip-Cross Section of AW 5083 AL-Alloy Verified with Grey Relation Analysis. Processes. 2021; 9(9):1485. https://doi.org/10.3390/pr9091485
Chicago/Turabian StyleMiškiv-Pavlík, Martin, and Jozef Jurko. 2021. "Machining of Inserts with PCD Cutting-Edge Technology and Determination of Optimum Machining Conditions Based on Roundness Deviation and Chip-Cross Section of AW 5083 AL-Alloy Verified with Grey Relation Analysis" Processes 9, no. 9: 1485. https://doi.org/10.3390/pr9091485