Metals

Research

13 pages, 2876 KiB

Open AccessArticle

Multi-Objective Optimization of Fiber Laser Cutting of Stainless-Steel Plates Using Taguchi-Based Grey Relational Analysis

by Yusuf Alptekin Turkkan, Muhammed Aslan, Alper Tarkan, Özgür Aslan, Celalettin Yuce and Nurettin Yavuz

Metals 2023, 13(1), 132; https://doi.org/10.3390/met13010132 - 9 Jan 2023

Cited by 8 | Viewed by 2485

Abstract

Stainless-steel has become a widely preferred material type in the marine, aerospace, sanitary, industrial equipment, and construction industries due to its superior corrosion resistance, high mechanic properties, high strength, formability, and thermal and electrical conductivity. In this study, a multi-objective optimization method based [...] Read more.

Stainless-steel has become a widely preferred material type in the marine, aerospace, sanitary, industrial equipment, and construction industries due to its superior corrosion resistance, high mechanic properties, high strength, formability, and thermal and electrical conductivity. In this study, a multi-objective optimization method based on grey relational analysis was employed to optimize the fiber laser-cutting parameters of cutting speed, focal position, frequency, and duty cycle. Surface roughness and kerf width, which are the two most important parameters that determine laser-cutting quality, were simultaneously optimized. In order to assign the optimum level of each parameter individually, the Taguchi technique was applied. The cutting surface morphology was examined according to the grey relational grade with a 3D optical profilometer, and maps of the cutting surfaces were created. According to the results achieved using Analysis of Variance (ANOVA), it was seen that the parameters that affected surface roughness and kerf width the most were duty cycle, with a contribution rate of 49.01%, and frequency, with a contribution rate of 31.2%. Frequency was the most important parameter in terms of multiple responses, with a contribution rate of 18.55%. Duty cycle and focal position were the second and third most effective parameters, respectively. It was determined that the optimum parameter values for minimum surface roughness and minimum kerf width that could be obtained with the fiber laser cutting of 20 mm thick AISI 304L (DIN EN 1.4301) material were 310 mm/min cutting speed, −11 mm focal position, 105 Hz frequency, and 60% duty cycle. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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22 pages, 10083 KiB

Open AccessArticle

Multi-Objective Optimization of Performance Indicators in Turning of AISI 1045 under Dry Cutting Conditions

by Adel T. Abbas, Abdulhamid A. Al-Abduljabbar, Magdy M. El Rayes, Faycal Benyahia, Islam H. Abdelgaliel and Ahmed Elkaseer

Metals 2023, 13(1), 96; https://doi.org/10.3390/met13010096 - 2 Jan 2023

Cited by 15 | Viewed by 2353

Abstract

In machining operations, minimizing the usage of resources such as energy, tools, costs, and production time, while maximizing process outputs such as surface quality and productivity, has a significant impact on the environment, process sustainability, and profit. In this context, this paper reports [...] Read more.

In machining operations, minimizing the usage of resources such as energy, tools, costs, and production time, while maximizing process outputs such as surface quality and productivity, has a significant impact on the environment, process sustainability, and profit. In this context, this paper reports on the utilization of advanced multi-objective algorithms for the optimization of turning-process parameters, mainly cutting speed, feed rate, and depth of cut, in the dry machining of AISI 1045 steel for high-efficient process. Firstly, a number of experimental tests were conducted in which cutting forces and cutting temperatures are measured. Then the material removal rate and the obtainable surface roughness were determined for the examined range of cutting parameters. Next, regression models were developed to formulate the relationships between the process parameters and the four process responses. After that, four different multi-objective optimization algorithms, (1) Gray Wolf Optimizer (GWO) and (2) Weighted Value Gray Wolf Optimizer (WVGWO), (3) Multi-Objective Genetic Algorithm (MOGA), and (4) Multi-Objective Pareto Search Algorithm (MOPSA), were applied. The results reveal that the optimal running conditions of the turning process of AISI 1045 steel obtained by WVGWO are a feed rate of 0.050 mm/rev, cutting speed of 156.5 m/min, and depth of cut of 0.57 mm. These conditions produce a high level of material removal rate of 4460.25 mm³/min, in addition to satisfying the surface quality with a roughness average of 0.719 µm. The optimal running conditions were found to be dependent on the objective outcomes’ order. Moreover, a comparative evaluation of the obtainable dimensional accuracy in both dry and wet turning operations was carried out, revealing a minimal relative error of 0.053% maximum between the two turning conditions. The results of this research work assist in obtaining precise, optimal, and cost-effective machining solutions, which can deliver a high-throughput, controllable, and robust manufacturing process when turning AISI 1045 steel. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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13 pages, 2842 KiB

Open AccessArticle

Laser Beam Machining of Tungsten Alloy: Experimental and Numerical Analysis

by Derzija Begic-Hajdarevic and Izet Bijelonja

Metals 2022, 12(11), 1863; https://doi.org/10.3390/met12111863 - 1 Nov 2022

Cited by 3 | Viewed by 1623

Abstract

Laser beam machining of various materials has found wide applications in the industry due to its advantages of high-speed machining, no tool wear and no vibration, precision and accuracy, low cost of machining, etc. Investigations into the laser beam machining of uncommon alloy [...] Read more.

Laser beam machining of various materials has found wide applications in the industry due to its advantages of high-speed machining, no tool wear and no vibration, precision and accuracy, low cost of machining, etc. Investigations into the laser beam machining of uncommon alloy are still limited and more research is needed in this field. In this paper, an analysis of the laser beam machining of tungsten alloy was performed, for cutting and drilling machining processes. First, an experimental analysis of microhardness and microstructure on the laser-cut samples was performed, and then the numerical simulation of the laser beam drilling process and its experimental validation was carried out. The experiments were carried out on a tungsten alloy plate of two different thicknesses, 0.5 and 1 mm. No significant changes in the microhardness, nor in the microstructure characteristics in the heat-affected zone (HAZ), were observed for the cutting conditions considered. A two-dimensional axisymmetric mathematical model for the simulation of the laser beam drilling process is solved by a finite volume method. The model was validated by comparing numerical and experimental results in terms of the size of HAZ and the size and shape of the drilled hole. Experimental and numerical results showed that HAZ is larger in the 0.5-mm-thick plate than in the 1-mm-thick plate under the same drilling conditions. Good agreement was observed between the experimental and numerical results. The developed model improves the understanding of the physical phenomena of laser beam machining and allows the optimization of laser and process parameters. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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18 pages, 11299 KiB

Open AccessArticle

Development of Tool Wear Standards and Wear Mechanism for Micro Milling Ti-6Al-4V Alloy

by Tao Zheng, Qinghua Song, Yicong Du and Zhanqiang Liu

Metals 2022, 12(5), 726; https://doi.org/10.3390/met12050726 - 24 Apr 2022

Cited by 5 | Viewed by 2891

Abstract

With the rapid development of high-precision-device technology, new demands are put forward for micro milling. The size effect and low cutting energy of micro milling make the process expensive and difficult, especially for Ti-6Al-4V alloys. The wear of the micro-milling cutter lacks corresponding [...] Read more.

With the rapid development of high-precision-device technology, new demands are put forward for micro milling. The size effect and low cutting energy of micro milling make the process expensive and difficult, especially for Ti-6Al-4V alloys. The wear of the micro-milling cutter lacks corresponding international standards and its cutting mechanism is complex. In this paper, four kinds of micro-milling cutters with different wear states were obtained by designing micro-milling experiments, and the wear process and wear mechanism were observed and analyzed. The cutter diameter reduction, end face wear, flank wear and edge radius are comprehensively analyzed. It is considered that the formulation of a micro-milling-cutter wear standard needs comprehensive consideration, and the wear of end face 30 μm, wear of flank 35 μm and tool diameter reduction 55 μm can be used as the failure criteria of the micro-milling cutter. The wear forms mainly include abrasion marks, material adhesion, built-up edges and micro-collapse blades. Adhesive wear exists in the whole cutting process and plays a major role. Abrasive wear, diffusion wear and oxidation wear will occur when the cutting temperature reaches the melting point of Co. The wear of the micro-milling cutter is analyzed more comprehensively, a new wear-failure standard is formulated and the complex wear mechanism is revealed. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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21 pages, 9835 KiB

Open AccessArticle

Drilling Parameters Analysis on In-Situ Al/B₄C/Mica Hybrid Composite and an Integrated Optimization Approach Using Fuzzy Model and Non-Dominated Sorting Genetic Algorithm

by Palanikumar Kayaroganam, Velavan Krishnan, Elango Natarajan, Senthilkumar Natarajan and Kanesan Muthusamy

Metals 2021, 11(12), 2060; https://doi.org/10.3390/met11122060 - 20 Dec 2021

Cited by 29 | Viewed by 3106

Abstract

In-situ hybrid metal matrix composites were prepared by reinforcing AA6061 aluminium alloy with 10 wt.% of boron carbide (B₄C) and 0 wt.% to 6 wt.% of mica. Machinability of the hybrid aluminium metal matrix composite was assessed by conducting drilling with [...] Read more.

In-situ hybrid metal matrix composites were prepared by reinforcing AA6061 aluminium alloy with 10 wt.% of boron carbide (B₄C) and 0 wt.% to 6 wt.% of mica. Machinability of the hybrid aluminium metal matrix composite was assessed by conducting drilling with varying input parameters. Surface texture of the hybrid composites and morphology of drill holes were examined through scanning electron microscope images. The influence of rotational speed, feed rate and % of mica reinforcement on thrust force and torque were studied and analysed. Statistical analysis and regression analysis were conducted to understand the significance of each input parameter. Reinforcement of mica is the key performance indicator in reducing the thrust force and torque in drilling of the selected material, irrespective of other parameter settings. Thrust force is minimum at mid-speed (2000 rpm) with the lowest feed rate (25 mm/min), but torque is minimum at highest speed (3000 rpm) with lowest feed rate (25 mm/min). Multi-objective optimization through a non-dominated sorting genetic algorithm has indicated that 1840 rpm of rotational speed, 25.3 mm/min of feed rate and 5.83% of mica reinforcement are the best parameters for obtaining the lowest thrust force of 339.68 N and torque of 68.98 N.m. Validation through experimental results confirms the predicted results with a negligible error (less than 0.1%). From the analysis and investigations, it is concluded that use of Al/10 wt.% B₄C/5.83 wt.% mica composite is a good choice of material that comply with European Environmental Protection Directives: 2000/53/CE-ELV for the automotive sector. The energy and production cost of the components can be very much reduced if the found optimum drill parameters are adopted in the production. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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21 pages, 6299 KiB

Open AccessArticle

MQL-Assisted Hard Turning of AISI D2 Steel with Corn Oil: Analysis of Surface Roughness, Tool Wear, and Manufacturing Costs

by Bogdan Arsene, Catalin Gheorghe, Flavius Aurelian Sarbu, Magdalena Barbu, Lucian-Ionel Cioca and Gavrila Calefariu

Metals 2021, 11(12), 2058; https://doi.org/10.3390/met11122058 - 19 Dec 2021

Cited by 19 | Viewed by 3745

Abstract

Precision hard turning (HT) gained more and more attention in the cutting industry in the last years due to continuous pressure of the global market for reducing costs, minimizing the environmental and health issues, and achieving a cleaner production. Therefore, dry cutting and [...] Read more.

Precision hard turning (HT) gained more and more attention in the cutting industry in the last years due to continuous pressure of the global market for reducing costs, minimizing the environmental and health issues, and achieving a cleaner production. Therefore, dry cutting and minimal quantity lubrication (MQL) became widely used in manufacturing to meet the environmental issues with respect to harmful cutting fluids (CFs). Vegetable oils, in MQL machining, are a promising solutions to petroleum-based CFs; however, the effects and performance on surface roughness and tool wear in HT with ceramic inserts remain unclear. To address this limitation, hardened AIDI D2 steel and pure corn oil, rich in saturated and monounsaturated fatty acids, cheap and widely available, have been used to conduct dry and MQL experiments at different cutting speed and feeds. Results show that corn oil is suitable as cutting lubricant in HT, creating a strong anti-wear and anti-friction lubricating film which improves the roughness with 10–15% and tool life with 15–20%, therefore reducing costs. Best surface roughness values (Ra = 0.151 μm, Rz = 0.887 μm, Rpk = 0.261 μm) were obtained at 180 m/min and 0.1 mm/rev. The analysis of variance shows that corn oil has statistical significance on roughness, validating the results. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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20 pages, 5531 KiB

Open AccessArticle

High-Pressure Cooling in Finishing Turning of Haynes 282 Using Carbide Tools: Haynes 282 and Inconel 718 Comparison

by Antonio Díaz-Álvarez, José Díaz-Álvarez, José Luis Cantero and María Henar Miguélez

Metals 2021, 11(12), 1916; https://doi.org/10.3390/met11121916 - 27 Nov 2021

Cited by 4 | Viewed by 1891

Abstract

Despite the interest of industry in nickel-based superalloys and its main features (high temperatures resistance, hardness, low thermal conductivity, among others), even today they are still materials that are difficult to cut. Cutting tools withstand both high pressures and temperatures highly localized at [...] Read more.

Despite the interest of industry in nickel-based superalloys and its main features (high temperatures resistance, hardness, low thermal conductivity, among others), even today they are still materials that are difficult to cut. Cutting tools withstand both high pressures and temperatures highly localized at the cutting area because of the elevated work hardening of the alloy and the problems for the cutting fluid to access the region, with the consequent strong tool wear. The use of cutting fluids at high pressures improves coolant access and heat removal. This paper analyzed the machining of Haynes 282 alloy by means of coated carbide tools under high-pressure cutting fluids at finishing conditions. Tests were developed at different cutting speeds and feeds quantifying the machining forces, surface roughness, tool wear, and tool life. Values of 45.9 min and R_a between 2 µm and 1 µm were obtained in this study for tool life and roughness, respectively, for the combination of cutting speed 50 m/min and feed 0.1 mm/rev. Likewise, a comparative analysis is included with the results obtained in previous works developed by the authors relating to the finishing turning of Haynes 282 and Inconel 718 under conventional pressure cooling. The comparative analysis with Inconel 718 is included in the study due to its importance within the nickel base superalloys being widely used in industry and widely analyzed in scientific literature. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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15 pages, 4439 KiB

Open AccessArticle

Modelling and Analysis of Surface Evolution on Turning of Hard-to-Cut CLARM 30NiCrMoV14 Steel Alloy

by Syed Muhammad Raza, Aqib Mashood Khan, Muhammad Umar Farooq, Asif Iqbal, Danil Yurievich Pimenov, Khaled Giasin and Kamil Leksycki

Metals 2021, 11(11), 1751; https://doi.org/10.3390/met11111751 - 31 Oct 2021

Cited by 10 | Viewed by 1739

Abstract

Industrial practitioners are working on predictive solutions for the precise evaluation of input parameters and processed surfaces of engineering materials. To aid the aeronautical industry, this study is an effort to develop the mathematical modelling for comprehensive surface analysis of input parameters and [...] Read more.

Industrial practitioners are working on predictive solutions for the precise evaluation of input parameters and processed surfaces of engineering materials. To aid the aeronautical industry, this study is an effort to develop the mathematical modelling for comprehensive surface analysis of input parameters and surface finish after dry machining of CLARM HBR, a steel alloy with attractive mechanical properties and wide applications in large caliber gun barrels and high-pressure vessels. Feed rate, rotational speed, and depth of cut were taken as quantitative parameters, whereas machining time was considered as a categorical factor with a classification of three levels. Response surface methodology (RSM) with a central component design has been used for the constitution of the experimental design, mathematical modelling, and analysis of developed models. Eighteen samples were prepared to perform the experimentation for the development of prediction models. The adequacy of the developed models was verified using analysis of variance (ANOVA), and the models were validated using confirmatory trial experiments, which revealed the experimental results agreeing with predictions. The feed rate was the most significant parameter in achieving the desired surface finish. An increase in rotational speed at a low feed rate resulted in very fine surface texture, as though it deteriorated the surface finish at higher feed rates. The superior surface quality 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. Overall, higher values of surface roughness were frecorded in the third level of process variable time. The developed empirical models are expected to aid manufacturers and machining practitioners in the prediction of the desired surface finish concerning different parameters before the experimentations. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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16 pages, 3096 KiB

Open AccessArticle

The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel

by Emin Salur, Mustafa Kuntoğlu, Abdullah Aslan and Danil Yurievich Pimenov

Metals 2021, 11(11), 1674; https://doi.org/10.3390/met11111674 - 20 Oct 2021

Cited by 64 | Viewed by 3917

Abstract

Minimum quantity lubrication (MQL) is a sustainable method that has been efficiently applied to achieve machinability improvements with various materials in recent years, such as hardened steels, superalloys, soft metals, and composites. This study is the first to focus on the performance evaluation [...] Read more.

Minimum quantity lubrication (MQL) is a sustainable method that has been efficiently applied to achieve machinability improvements with various materials in recent years, such as hardened steels, superalloys, soft metals, and composites. This study is the first to focus on the performance evaluation of MQL and dry milling environments with AISI 1040 steel. The tool wear, cutting temperature, and power consumption were considered as the quality responses while cutting speed, feed rate and machining environment are taken as input parameters. The effects of the influential factors are analyzed using analysis of variance (ANOVA) and bar charts. Additionally, Taguchi signal-to-noise (S/N) ratios are utilized in order to determine the optimum parameters for the best quality responses. The results show that the MQL system provides better performance compared to dry milling by reducing the tool wear, cutting temperature, and power consumption. According to the ANOVA results, the cutting environment affects the cutting temperature (37%) and power consumption (94%), while cutting speed has importance effects on the tool wear (74%). A lower cutting speed (100 m/min) and feed rate (0.10 mm/rev) should be selected under MQL conditions to ensure minimum tool wear and power consumption; however, a higher feed rate (0.15 mm/rev) needs to be selected along with a low cutting speed and MQL conditions to ensure better temperatures. A comparative evaluation is carried out on the tool wear, cutting temperature, and power consumption under MQL and dry environments. This investigation is expected to contribute to the current literature, highlighting the superiority of sustainable methods in the milling of industrially important materials. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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17 pages, 4200 KiB

Open AccessArticle

Prediction of Tool Shape in Electrical Discharge Machining of EN31 Steel Using Machine Learning Techniques

by Arminder Singh Walia, Vineet Srivastava, Prashant S Rana, Nalin Somani, Nitin Kumar Gupta, Gurminder Singh, Danil Yurievich Pimenov, Tadeusz Mikolajczyk and Navneet Khanna

Metals 2021, 11(11), 1668; https://doi.org/10.3390/met11111668 - 20 Oct 2021

Cited by 21 | Viewed by 2481

Abstract

In the electrical discharge machining (EDM) process, especially during the machining of hardened steels, changes in tool shape have been identified as one of the major problems. To understand the aforesaid dilemma, an initiative was undertaken through this experimental study. To assess the [...] Read more.

In the electrical discharge machining (EDM) process, especially during the machining of hardened steels, changes in tool shape have been identified as one of the major problems. To understand the aforesaid dilemma, an initiative was undertaken through this experimental study. To assess the distortion in tool shape that occurs during the machining of EN31 tool steel, variations in tool shape were examined by monitoring the roundness of the tooltip before and after machining with a coordinate measuring machine. The change in out-of-roundness of the tooltip varied from 5.65 to 37.8 µm during machining under different experimental conditions. It was revealed that the input current, the pulse on time, and the pulse off time had most significant effect in terms of changes in the out-of-roundness values during machining. Machine learning techniques (decision tree, random forest, generalized linear model, and neural network) were applied for the prediction of changes in tool shape. It was observed that the results predicted by the random forest technique were more convincing. Subsequently, it was gathered from this examination that the usage of the random forest technique for the prediction of changes in tool shape yielded propitious outcomes, with high accuracy (93.67%), correlation (0.97), coefficient of determination (0.94), and mean absolute error (1.65 µm) values. Hence, it was inferred that the random forest technique provided better results in terms of the prediction of tool shape. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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18 pages, 18092 KiB

Open AccessArticle

Optimizing the High-Performance Milling of Thin Aluminum Alloy Plates Using the Taguchi Method

by Cheng-Hsien Kuo and Zi-Yi Lin

Metals 2021, 11(10), 1526; https://doi.org/10.3390/met11101526 - 26 Sep 2021

Cited by 8 | Viewed by 2345

Abstract

Most aerospace parts are thin walled and made of aluminum or titanium alloy that is machined to the required shape and dimensions. Deformation is a common issue. Although the reduced cutting forces used in high-speed milling generate low residual stress, the problem of [...] Read more.

Most aerospace parts are thin walled and made of aluminum or titanium alloy that is machined to the required shape and dimensions. Deformation is a common issue. Although the reduced cutting forces used in high-speed milling generate low residual stress, the problem of deformation cannot be completely resolved. In this work, we emphasized that choosing the correct cutting parameters and machining techniques could increase the cutting performance and surface quality and reduce the deformation of thin plates. In this study, a part made of a thin 6061 aluminum alloy plate was machined by high-speed milling (HSM), and a Taguchi L16 orthogonal array was used to optimize the following parameters: linear velocity, feed per tooth, cutting depth, cutting width, and toolpath. The impact of cutting parameters on the degree of deformation, surface roughness, as well as the cutting force on the thin plate were all investigated. The results showed that the experimental parameters for the optimal degree of deformation were A1 (linear velocity 450 mm/min), B1 (feed per tooth 0.06 mm/tooth), C1 (cutting depth 0.3 mm), D4 (cutting width 70%), and E4 (rough zigzag). Feed per tooth was the most significant control factor, with a contribution as high as 63.5%. It should also be mentioned that, according to the factor response of deformation, there was a lower value of feed per tooth and less deformation. Furthermore, the feed per tooth and the cutting depth decreased and the surface roughness increased. The cutting force rose or fell with an increase or decrease of cutting depth. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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25 pages, 4966 KiB

Open AccessArticle

Experimental Investigations and Pareto Optimization of Fiber Laser Cutting Process of Ti6Al4V

by Jay Vora, Rakesh Chaudhari, Chintan Patel, Danil Yurievich Pimenov, Vivek K. Patel, Khaled Giasin and Shubham Sharma

Metals 2021, 11(9), 1461; https://doi.org/10.3390/met11091461 - 15 Sep 2021

Cited by 37 | Viewed by 3277

Abstract

In the current study, laser cutting of Ti6Al4V was accomplished using Taguchi’s L₉ orthogonal array (OA). Laser power, cutting speed, and gas pressure were selected as input process parameters, whereas surface roughness (SR), kerf width, dross height, and material removal [...] Read more.

In the current study, laser cutting of Ti6Al4V was accomplished using Taguchi’s L₉ orthogonal array (OA). Laser power, cutting speed, and gas pressure were selected as input process parameters, whereas surface roughness (SR), kerf width, dross height, and material removal rate (MRR) were considered as output variables. The effects of input variables were analyzed through the analysis of variance (ANOVA), main effect plots, residual plots, and contour plots. A heat transfer search algorithm was used to optimize the parameters for the single objective function including higher MRR, minimum SR, minimum dross, and minimum kerf. A multi-objective heat transfer search algorithm was used to create non-dominant optimal Pareto points, giving unique optimal solutions with the corresponding input parameters. For better understanding and ease of selection of input parameters in industry and by scientists, a Pareto graph (2D and 3D graph) is generated from the Pareto points. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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25 pages, 10857 KiB

Open AccessArticle

Analysis and Optimization of Process Parameters in Abrasive Waterjet Contour Cutting of AISI 304L

by Jennifer Milaor Llanto, Ana Vafadar, Muhammad Aamir and Majid Tolouei-Rad

Metals 2021, 11(9), 1362; https://doi.org/10.3390/met11091362 - 30 Aug 2021

Cited by 20 | Viewed by 3247

Abstract

Abrasive waterjet machining is applied in various industries for contour cutting of heat-sensitive and difficult-to-cut materials like austenitic stainless steel 304L, with the goal of ensuring high surface integrity and efficiency. In alignment with this manufacturing aspiration, experimental analysis and optimization were carried [...] Read more.

Abrasive waterjet machining is applied in various industries for contour cutting of heat-sensitive and difficult-to-cut materials like austenitic stainless steel 304L, with the goal of ensuring high surface integrity and efficiency. In alignment with this manufacturing aspiration, experimental analysis and optimization were carried out on abrasive waterjet machining of austenitic stainless steel 304L with the objectives of minimizing surface roughness and maximizing material removal rate. In this machining process, process parameters are critical factors influencing contour cutting performance. Accordingly, Taguchi’s S/N ratio method has been used in this study for the optimization of process parameters. Further in this work, the impacts of input parameters are investigated, including waterjet pressure, abrasive mass flow rate, traverse speed and material thickness on material removal rate and surface roughness. The study reveals that an increasing level of waterjet pressure and abrasive mass flow rate achieved better surface integrity and higher material removal values. The average S/N ratio results indicate an optimum value of waterjet pressure at 300 MPa and abrasive mass flow rate of 500 g/min achieved minimum surface roughness and maximum material removal rate. It was also found that an optimized value of a traverse speed at 90 mm/min generates the lowest surface roughness and 150 mm/min produces the highest rate of material removed. Moreover, analysis of variance in the study showed that material thickness was the most influencing parameter on surface roughness and material removal rate, with a percentage contribution ranging 90.72–97.74% and 65.55–78.17%, respectively. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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14 pages, 5733 KiB

Open AccessArticle

Tool Wear Analysis during Ultrasonic Assisted Turning of Nimonic-90 under Dry and Wet Conditions

by Jay Airao, Chandrakant K. Nirala, Luis Noberto López de Lacalle and Navneet Khanna

Metals 2021, 11(8), 1253; https://doi.org/10.3390/met11081253 - 7 Aug 2021

Cited by 22 | Viewed by 2501

Abstract

Nickel-based superalloys are widely used in the aerospace, automotive, marine and medical sectors, owing to their high mechanical strength and corrosion resistance. However, they exhibit poor machinability due to low thermal conductivity, high shear modulus, strain hardening, etc. Various modifications have been incorporated [...] Read more.

Nickel-based superalloys are widely used in the aerospace, automotive, marine and medical sectors, owing to their high mechanical strength and corrosion resistance. However, they exhibit poor machinability due to low thermal conductivity, high shear modulus, strain hardening, etc. Various modifications have been incorporated into existing machining techniques to address these issues. One such modification is the incorporation of ultrasonic assistance to turning operations. The assisted process is popularly known as ultrasonic assisted turning (UAT), and uses ultrasonic vibration to the processing zone to cut the material. The present article investigates the effect of ultrasonic vibration on coated carbide tool wear for machining Nimonic-90 under dry and wet conditions. UAT and conventional turning (CT) were performed at constant cutting speed, feed rate and depth of cut. The results show that the main wear mechanisms were abrasion, chipping, notch wear and adhesion of the built-up edge in both processes. However, by using a coolant, the formation of the built-up edge was reduced. CT and UAT under dry conditions showed an approximate reduction of 20% in the width of flank wear compared to CT and UAT under wet conditions. UAT showed approximate reductions of 6–20% in cutting force and 13–27% in feed force compared to the CT process. The chips formed during UAT were thinner, smoother and shorter than those formed during CT. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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17 pages, 5113 KiB

Open AccessArticle

Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study

by Nagarajan Lenin, Mahalingam Sivakumar, Gurusamy Selvakumar, Devaraj Rajamani, Vinothkumar Sivalingam, Munish Kumar Gupta, Tadeusz Mikolajczyk and Danil Yurievich Pimenov

Metals 2021, 11(7), 1105; https://doi.org/10.3390/met11071105 - 11 Jul 2021

Cited by 26 | Viewed by 2568

Abstract

In this work, wire electrical discharge machining (WEDM) of aluminum (LM25) reinforced with fly ash and boron carbide (B4C) hybrid composites was performed to investigate the influence of reinforcement wt% and machining parameters on the performance characteristics. The hybrid composite specimens were fabricated [...] Read more.

In this work, wire electrical discharge machining (WEDM) of aluminum (LM25) reinforced with fly ash and boron carbide (B4C) hybrid composites was performed to investigate the influence of reinforcement wt% and machining parameters on the performance characteristics. The hybrid composite specimens were fabricated through the stir casting process by varying the wt% of reinforcements from 3 to 9. In the machinability studies, the WEDM process control parameters such as gap voltage, pulse-on time, pulse-off time, and wire feed were varied to analyze their effects on machining performance including volume removal rate and surface roughness. The WEDM experiments were planned and conducted through the L27 orthogonal array approach of the Taguchi methodology, and the corresponding volume removal rate and surface roughness were measured. In addition, the multi-parametric ANOVA was performed to examine the statistical significance of the process control parameters on the volume removal rate and surface roughness. Furthermore, the spatial distribution of the parameter values for both the responses were statistically analyzed to confirm the selection of the range of the process control parameters. Finally, the quadratic multiple linear regression models (MLRMs) were formulated based on the correlation between the process control parameters and output responses. The Grass–Hooper Optimization (GHO) algorithm was proposed in this work to identify the optimal process control parameters through the MLRMs, in light of simultaneously maximizing the volume removal rate and minimizing the surface roughness. The effectiveness of the proposed GHO algorithm was tested against the results of the particle swarm optimization and moth-flame optimization algorithms. From the results, it was identified that the GHO algorithm outperformed the others in terms of maximizing volume removal rate and minimizing the surface roughness values. Furthermore, the confirmation experiment was also carried out to validate the optimal combination of process control parameters obtained through the GHO algorithm. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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14 pages, 5357 KiB

Open AccessArticle

The Effect of TiN-, TiCN-, TiAlN-, and TiSiN Coated Tools on the Surface Defects and Geometric Tolerances of Holes in Multi-Spindle Drilling of Al2024 Alloy

by Muhammad Aamir, Adrian Davis, William Keeble, Ugur Koklu, Khaled Giasin, Ana Vafadar and Majid Tolouei-Rad

Metals 2021, 11(7), 1103; https://doi.org/10.3390/met11071103 - 11 Jul 2021

Cited by 8 | Viewed by 3397

Abstract

The integrity of machined holes depends on many parameters, some of which are related to the cutting tool (geometry, coating, material). Other influential parameters are related to the machining process variables (spindle speed, feed rate, workpiece material), all of which can affect the [...] Read more.

The integrity of machined holes depends on many parameters, some of which are related to the cutting tool (geometry, coating, material). Other influential parameters are related to the machining process variables (spindle speed, feed rate, workpiece material), all of which can affect the quality of the hole and drilling induced damage on its surface. This study investigates the effect of uncoated tools and four types of tool coatings (TiN-, TiCN-, TiAlN-, and TiSiN) on the hole quality and its microstructure. The study analyzed several hole geometrical metrics, namely hole size, circularity, cylindricity, and perpendicularity of an Al2024 aluminum alloy using a multi-spindle drilling process that utilizes three drills capable of creating multiple holes simultaneously. The results showed that the uncoated carbide drill gave a high-hole quality at low spindle speed. Regarding the coated drills, TiCN coated drills produced holes with the least deviation, circularity, cylindricity and perpendicularity at high spindle speeds. TiSiN–carbide coated drills produced the most oversized holes and noticeable damage and deformations on their surface following TiAlN and TiN. The common surface damage found on the inner hole surface was smearing, feed marks, and metal debris adhesion. The ANOVA results revealed that the tool type had the highest percentage contribution that mainly affected the hole quality. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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17 pages, 3150 KiB

Open AccessArticle

Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

by Fernando Veiga, Alain Gil Del Val, Mari Luz Penalva, Octavio Pereira, Alfredo Suárez and Luis Norberto López de Lacalle Marcaide

Metals 2021, 11(7), 1009; https://doi.org/10.3390/met11071009 - 24 Jun 2021

Cited by 1 | Viewed by 1904

Abstract

A low-frequency-assisted boring operation is a key cutting process in the aircraft manufacturing sector when drilling deep holes to avoid chip clogging based on chip breakage and, consequently, to reduce the temperature level in the cutting process. This paper proposes a predicted force [...] Read more.

A low-frequency-assisted boring operation is a key cutting process in the aircraft manufacturing sector when drilling deep holes to avoid chip clogging based on chip breakage and, consequently, to reduce the temperature level in the cutting process. This paper proposes a predicted force model based on a commercial control-supported chip breaking function without external vibration devices in the boring operations. The model was fitted by conventional boring measurements and was validated by vibration boring experiments with different ranges of amplitude and frequency. The average prediction error is around 10%. The use of a commercial function makes the model more attractive for the industry because there is no need for intrusive vibration sensors. The low-frequency-assisted boring (LFAB) operations foster the chip breakage. Finally, the model is generic and can be used for different cutting materials and conditions. Roughness is improved by 33% when vibration conditions are optimal, considered as a vibration amplitude of half the feed per tooth. This paper presents, as a novelty, the analysis of low-frequency vibration parameters in boring processes and their effect on chip formation and internal hole roughness. This has a practical significance for the definition of a methodology based on the torque model for the selection of conditions on other hole-making processes, cutting parameters and/or materials. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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9 pages, 4093 KiB

Open AccessArticle

Analysis of Hole Quality and Chips Formation in the Dry Drilling Process of Al7075-T6

by Numan Habib, Aamer Sharif, Aqib Hussain, Muhammad Aamir, Khaled Giasin, Danil Yurievich Pimenov and Umair Ali

Metals 2021, 11(6), 891; https://doi.org/10.3390/met11060891 - 29 May 2021

Cited by 22 | Viewed by 3233

Abstract

Millions of holes are produced in many industries where efficient drilling is considered the key factor in their success. High-quality holes are possible with the proper selection of drilling process parameters, appropriate tools, and machine setup. This paper deals with the effects of [...] Read more.

Millions of holes are produced in many industries where efficient drilling is considered the key factor in their success. High-quality holes are possible with the proper selection of drilling process parameters, appropriate tools, and machine setup. This paper deals with the effects of drilling parameters such as spindle speed and feed rate on the chips analysis and the hole quality like surface roughness, hole size, circularity, and burr formation. Al7075-T6 alloy, commonly used in the aerospace industry, was used for the drilling process, and the dry drilling experiments were performed using high-speed steel drill bits. Results have shown that surface roughness decreased with the increase in spindle speed and increased with the increase in the feed rate. The hole size increased with the high spindle speed, whereas the impact of spindle speed on circularity error was found insignificant. Furthermore, short and segmented chips were achieved at a high feed rate and low spindle speed. The percentage contribution of each input parameter on the output drilling parameters was evaluated using analysis of variance (ANOVA). Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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13 pages, 8749 KiB

Open AccessArticle

Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

by Muhammad Aamir, Khaled Giasin, Majid Tolouei-Rad, Israr Ud Din, Muhammad Imran Hanif, Ugur Kuklu, Danil Yurievich Pimenov and Muhammad Ikhlaq

Metals 2021, 11(6), 854; https://doi.org/10.3390/met11060854 - 23 May 2021

Cited by 20 | Viewed by 2967

Abstract

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation [...] Read more.

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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22 pages, 2635 KiB

Open AccessArticle

Experimental Analysis and Optimization of EDM Parameters on HcHcr Steel in Context with Different Electrodes and Dielectric Fluids Using Hybrid Taguchi-Based PCA-Utility and CRITIC-Utility Approaches

by Manjunath Patel Gowdru Chandrashekarappa, Sandeep Kumar, Jagadish, Danil Yurievich Pimenov and Khaled Giasin

Metals 2021, 11(3), 419; https://doi.org/10.3390/met11030419 - 4 Mar 2021

Cited by 81 | Viewed by 3615

Abstract

Industries demand stringent requirements towards economical machining without hindering the surface quality while cutting high carbon high chromium (HcHcr) steel. Electrical discharge machining (EDM) of HcHcr steel aims at reducing machining cost (i.e., maximize material removal rate (MRR) and minimize tool wear rate [...] Read more.

Industries demand stringent requirements towards economical machining without hindering the surface quality while cutting high carbon high chromium (HcHcr) steel. Electrical discharge machining (EDM) of HcHcr steel aims at reducing machining cost (i.e., maximize material removal rate (MRR) and minimize tool wear rate (TWR)) with good surface quality (i.e., minimize surface roughness (SR)). A comparative study was carried out on EDM of HcHcr D2 steel (DIN EN ISO 4957) by applying Taguchi L₁₈ experimental design considering different electrode materials (copper, graphite, and brass), dielectric fluids (distilled water and kerosene), peak current, and pulse-on-time. The process performances were analyzed with respect to material removal rate, surface roughness, and tool wear rate. Pareto analysis of variance was employed to estimate the significance of the process variables and their optimal levels for achieving lower SR and TWR and higher MRR. Hybrid Taguchi-CRITIC-Utility and Taguchi-PCA-Utility methods were implemented to determine the optimal EDM parameters. Higher MRR of 0.0632 g/min and lower SR of 1.68 µm and TWR of 0.012 g/min was attained by graphite electrode in presence of distilled water as dielectric fluid compared to the brass and copper. Additionally, a metallographic analysis was carried out to study the surface integrity on the machined surfaces. Micrographic analysis of the optimal conditions showed lower surface roughness and fewer imperfections (lesser impression, waviness surface, and micro-cracks) compared to worst conditions. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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24 pages, 5860 KiB

Open AccessArticle

Experimental Investigation and Multi-Response Optimization of Machinability of AA5005H34 Using Composite Desirability Coupled with PCA

by Mohsin Iqbal Qazi, Muhammad Abas, Razaullah Khan, Waqas Saleem, Catalin Iulian Pruncu and Muhammad Omair

Metals 2021, 11(2), 235; https://doi.org/10.3390/met11020235 - 31 Jan 2021

Cited by 24 | Viewed by 3304

Abstract

Minimum quantity lubricant (MQL) is an advanced technique in machining to achieve sustainability, productivity, higher precision, economic benefits, and a reduction in carbon footprints. The present research work aims to investigate the effect of the cutting process parameters of the end milling of [...] Read more.

Minimum quantity lubricant (MQL) is an advanced technique in machining to achieve sustainability, productivity, higher precision, economic benefits, and a reduction in carbon footprints. The present research work aims to investigate the effect of the cutting process parameters of the end milling of AA5005H34 material under dry and MQL cutting environments. The key performance indicators of machining include the surface roughness profile, the material removal rate, and tool wear. Surface roughness parameters are measured with the help of the Mitutoyo surface roughness tester, and the cutting tool wear is measured according to the ISO 8688-2:1989 standard using a scanning electron microscope (SEM). Sixteen experiments are designed based on the Taguchi orthogonal array mixture design. Single responses are optimized based on signal to noise ratios, while for multi-response optimization composite desirability function coupled with principal component analysis is applied. Analysis of variance (ANOVA) results revealed that the feed rate followed by spindle speed, axial depth of the cut, width of the cut, and cutting environment are the most significant factors contributing to the surface roughness profile, material removal rate, and tool wear. The optimized parameters are obtained as cutting speed of 3000 rev/min, feed rate of 350 mm/min, axial depth of cut of 2 mm, and width of cut of 6 mm under an MQL environment. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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18 pages, 2542 KiB

Open AccessArticle

Effect of Tool Coating and Cutting Parameters on Surface Roughness and Burr Formation during Micromilling of Inconel 718

by Atif Muhammad, Munish Kumar Gupta, Tadeusz Mikołajczyk, Danil Yurievich Pimenov and Khaled Giasin

Metals 2021, 11(1), 167; https://doi.org/10.3390/met11010167 - 18 Jan 2021

Cited by 35 | Viewed by 4191

Abstract

Surface roughness and burr formation are among the most important surface quality metrics which determine the quality of the fabricated parts. High precision machined microparts with complex features require micromachining process to achieve the desired yet stringent surface finish and dimensional accuracy. In [...] Read more.

Surface roughness and burr formation are among the most important surface quality metrics which determine the quality of the fabricated parts. High precision machined microparts with complex features require micromachining process to achieve the desired yet stringent surface finish and dimensional accuracy. In this research, the effect of cutting speed (m/min), feed rate (µm/tooth), depth of cut (µm) and three types of tool coating (AlTiN, nACo and TiSiN) were analyzed to study their effect on surface roughness and burr formation during the micromachining of Inconel 718. The analysis was carried out using an optical profilometer, scanning electron microscope and statistical technique. Machining tests were performed at low speed with a feed rate (µm/tooth) below the cutting-edge radius for 10 mm cutting length using a carbide tool of 0.5 mm diameter on a CNC milling machine. From this research, it was determined that the depth of cut was the main factor affecting burr formation, while cutting velocity was the main factor affecting the surface roughness. In addition, cutting tool coating did not significantly affect either surface roughness or burr formation due to the difference in coefficient of friction. The types of burr formed during micromilling of Inconel 718 were mainly influenced by the depth of cut and feed rate (µm/tooth) and were not affected by the cutting velocity. It was also concluded that the results for the surface finish at low-speed machining are comparable to that of transition and high-speed machining, while the burr width found during confirmation experiments at low-speed machining was also within an acceptable range. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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16 pages, 1462 KiB

Open AccessArticle

Application of Type-2 Fuzzy AHP-ARAS for Selecting Optimal WEDM Parameters

by Binayak Sen, Syed Abou Iltaf Hussain, Archisman Das Gupta, Munish Kumar Gupta, Danil Yurievich Pimenov and Tadeusz Mikołajczyk

Metals 2021, 11(1), 42; https://doi.org/10.3390/met11010042 - 27 Dec 2020

Cited by 40 | Viewed by 2673

Abstract

Machining of the nickel-based alloy is very demanding due to its extreme mechanical properties, for example, higher fatigue strength, better corrosion and creep resistance feature, substantial work hardening capability, and appreciable tensile and shear strength. Owing to these properties, the selection of machining [...] Read more.

Machining of the nickel-based alloy is very demanding due to its extreme mechanical properties, for example, higher fatigue strength, better corrosion and creep resistance feature, substantial work hardening capability, and appreciable tensile and shear strength. Owing to these properties, the selection of machining parameters is a major challenge for modern machining industries. Therefore, the present experimental work is carried out to select the best parametric combination of the wire electrical discharge machining (WEDM) machine for reducing machining cost and human effort. The Trapezoidal Interval Type-2 fuzzy number (T2FS) integrated Analytical Hierarchy Process (AHP)-based Additive Ratio Assessment (ARAS) method is used for selecting the best WEDM process parameters of Inconel-800 superalloy. Finally, the results were compared with some existing multi-criteria decision-making methods to confirm the validity of the adopted method. The comparison shows that Type-2 Fuzzy AHP-ARAS synergy can help to formulate the problem and facilitate the assessment and ranking of WEDM process parameters when multiple criteria are jointly considered. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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17 pages, 2187 KiB

Open AccessArticle

Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel

by Angelos P. Markopoulos, Nikolaos E. Karkalos, Mozammel Mia, Danil Yurievich Pimenov, Munish Kumar Gupta, Hussein Hegab, Navneet Khanna, Vincent Aizebeoje Balogun and Shubham Sharma

Metals 2020, 10(12), 1650; https://doi.org/10.3390/met10121650 - 7 Dec 2020

Cited by 22 | Viewed by 2979

Abstract

The hardened tool steel AISI O1 has increased strength, hardness, and wear resistance, which affects the complexity of the machining process. AISI O1 has also been classified as difficult to cut material hence optimum cutting parameters are required for the sustainable machining of [...] Read more.

The hardened tool steel AISI O1 has increased strength, hardness, and wear resistance, which affects the complexity of the machining process. AISI O1 has also been classified as difficult to cut material hence optimum cutting parameters are required for the sustainable machining of the alloy. In this work, the effect of feed peer tooth (f_z), cutting speed (v_c), cutting of depth (a_p) on surface roughness (Ra, Rt), cutting force (F_x, F_y), cutting power (P_c), machining cost (C_i), and carbon dioxide (Ene) were investigated during the slot milling process of AISI O1 hardened steel. A regression analysis was carried out on the obtained experimental results and the induction of nonlinear mathematical equations of surface roughness, cutting force, cutting power, and machining cost with a high coefficient of determination (R² = 90.62–98.74%) were deduced. A sustainability assessment model is obtained for optimal and stable levels of design variables when slot milling AISI O1 tool steel. Stable indicators to ensure personal health and safety of operation, P1 values were set to “1” at a cutting speed of 20 m/min or 43.3 m/min and “2” at a cutting speed of 66.7 m/min or 90 m/min. It is revealed that for eco-benign machining of AISI O1, the optimum parameters of 0.01 mm/tooth, 20 m/min, and 0.1 mm should be adopted for feed rate, cutting speed, and depth of cut respectively. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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18 pages, 6353 KiB

Open AccessArticle

Sustainable Manufacturing and Parametric Analysis of Mild Steel Grade 60 by Deploying CNC Milling Machine and Taguchi Method

by Shakir Azim, Sahar Noor, Qazi Salman Khalid, Aqib Mashood Khan, Danil Yurievich Pimenov, Imran Ahmad, Abdur Rehman Babar and Catalin I. Pruncu

Metals 2020, 10(10), 1303; https://doi.org/10.3390/met10101303 - 29 Sep 2020

Cited by 15 | Viewed by 3673

Abstract

Design and manufacturing are the key steps in the sustainable manufacturing of any product to be produced. Within the perspective of injection molds production, increased competitiveness and repeated changes in the design require a complete optimized manufacturing process. Local and minor improvements in [...] Read more.

Design and manufacturing are the key steps in the sustainable manufacturing of any product to be produced. Within the perspective of injection molds production, increased competitiveness and repeated changes in the design require a complete optimized manufacturing process. Local and minor improvements in the milling process do not generally lead to an optimized manufacturing process. The goal of the new geometry and parametric analysis of the mould is to reduce the quality issues in mild steel grade 60. In this explicit research, the surface roughness (smoothness) of indigenously produced injection moulds in the local market in Pakistan is investigated. The CNC milling machine (five-axis) is used for the manufacturing of an injection mould, and the Taguchi method of the design of the experiment is applied for parameters optimization. Hence, the overall process is assisted in balancing the milling machine parameters to trim down the surface roughness issue in mild steel moulds and increase their sustainability. The spindle speed (rpm), the depth of cut (mm), and the feed rate (mm/rev) are considered as input variables for process optimization, and the experiments are performed on mild steel grade 60. It is deduced that the combination of a spindle speed of 800 rpm, feed rate of 10 mm/rev and depth of cut of 0.5 mm is the best case in case of minimum surface roughness, which leads to sustainable products. It is also deduced from ANOVA, that the spindle speed is a factor that affects the surface roughness of mild steel products, while the feed rate turns out to be insignificant. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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22 pages, 4384 KiB

Open AccessArticle

Sustainability-Based Optimization of the Rotary Turning of the Hardened Steel

by Trung-Thanh Nguyen, Quoc-Dung Duong and Mozammel Mia

Metals 2020, 10(7), 939; https://doi.org/10.3390/met10070939 - 12 Jul 2020

Cited by 15 | Viewed by 2692

Abstract

The rotary turning is an effective manufacturing method to machine hardened metals due to longer tool life, higher production rate, and acceptable quality. However, sustainability-based optimization of the rotary turning has not been thoroughly considered because of the huge efforts. This study presents [...] Read more.

The rotary turning is an effective manufacturing method to machine hardened metals due to longer tool life, higher production rate, and acceptable quality. However, sustainability-based optimization of the rotary turning has not been thoroughly considered because of the huge efforts. This study presents an optimization to enhance the energy efficiency (EF_R), turning cost (CT), average roughness (R_a), and the operational safety (POS) for the rotary turning of the hardened steel. Four key process parameters considered are the inclined angle (α), depth of cut (a_p), feed rate (f), and cutting speed (v_c). The improved Kriging (IK) models were used to construct the relations between the parameters and performances. The optimum varied factors were obtained utilizing the neighborhood cultivation genetic algorithm (NCGA). The findings revealed that the performance models are primarily affected by the feed rate, depth of cut, speed, and inclined angle, respectively. The optimal values of the α, a_p, f, and v_c are 26°, 0.44 mm, 0.37 mm/rev, and 200 mm/min, respectively. The improvements in energy efficiency, average roughness, and cost are 8.91%, 20.00%, and 14.75%, as compared to the initial values. Moreover, the NCGA may perform an efficient operation to obtain the optimal outcomes, as compared to conventional algorithms. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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16 pages, 5807 KiB

Open AccessArticle

Tool Performance Optimization While Machining Aluminium-Based Metal Matrix Composite

by Usama Umer, Mustufa Haider Abidi, Jaber Abu Qudeiri, Hisham Alkhalefah and Hossam Kishawy

Metals 2020, 10(6), 835; https://doi.org/10.3390/met10060835 - 24 Jun 2020

Cited by 7 | Viewed by 2583

Abstract

Finite element (FE) models and the multi objective genetic algorithm (MOGA-II) have been applied for tool performance optimization while machining aluminum-based metal matrix composites. The developed and verified FE models are utilized to generate data for the full factorial design of experiment (DOE) [...] Read more.

Finite element (FE) models and the multi objective genetic algorithm (MOGA-II) have been applied for tool performance optimization while machining aluminum-based metal matrix composites. The developed and verified FE models are utilized to generate data for the full factorial design of experiment (DOE) plan. The FE models consist of a heterogenous workpiece, which assumes uniform distribution of reinforced particles according to size and volume fraction. Cutting forces, chip morphology, temperature contours, stress distributions in the workpiece and tool by altering cutting speed, feed rate, and reinforcement particle size can be estimated using developed FE models. The DOE data are then utilized to develop response surfaces using radial basis functions. To reduce computational time, these response surfaces are used as solver for optimization runs using MOGA-II. Tool performance has been optimized with regard to cutting temperatures and stresses while setting a limit on specific cutting energy. Optimal solutions are found with low cutting speed and moderate feed rates for each particle size metal matrix composite (MMC). Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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12 pages, 6321 KiB

Open AccessArticle

Abrasive Disc Performance in Dry-Cutting of Medium-Carbon Steel

by Naiara Ortega, Vitaliy Martynenko, Daniela Perez, Daniel Martinez Krahmer, Luis Norberto López de Lacalle and Eneko Ukar

Metals 2020, 10(4), 538; https://doi.org/10.3390/met10040538 - 21 Apr 2020

Cited by 5 | Viewed by 5438

Abstract

Abrasive-cutting processes are widely used to obtain semi-finished products from metal bars, slabs, or tubes. Thus, the abrasive cutting-off process is applied when requiring precision cutting and productivity at a moderate price. Cut-off tools are discs composed of small abrasive particles embedded in [...] Read more.

Abrasive-cutting processes are widely used to obtain semi-finished products from metal bars, slabs, or tubes. Thus, the abrasive cutting-off process is applied when requiring precision cutting and productivity at a moderate price. Cut-off tools are discs composed of small abrasive particles embedded in a bonding material, called the binder. This work aims to compare the cutting performance of discs with different composition, in dry cutting of steel bars. To do that, disc wear was measured and disc final topography was digitalized in order to determine both disc surface wear patterns and if the abrasive particles bonding into the binder matrix was affected. In addition, X-Ray inspection gave information about the abrasive grit-binder bonding. Therefore, the method here presented allows identifying discs with a superior abrasive-cutting capability, by combining profilometry and tomography to define micrometrical aspects, grit size, and binder matrix structure. Results led to the conclusion that discs with high grit size and protrusion, high grit retention by bond material, and closer mesh of fiberglass matrix binder were the optimal solution. Full article

(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)

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