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RISS 인기검색어
- 검색키워드
- 저자 : Debabrata Dhupal (검색결과 2 건)
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Sudhansu Ranjan Das,Debabrata Dhupal,Amaresh Kumar 대한기계학회 2015 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.29 No.10
This experimental investigation deals with dry hard turning of AISI 4140 steel using PVD-TiN coated Al2O3+TiCN mixed ceramic inserts. The combined effect of cutting parameters (cutting speed, feed and depth of cut) on performance characteristics such as surfaceroughness and flank wear is explored by Full factorial design (FFD) and analysis of variance (ANOVA). The results show that feed is theprincipal cutting parameter influencing surface roughness, followed by cutting speed. However, flank wear is affected by the cuttingspeed and interaction of feed-depth of cut, although depth of cut has not been found statistically significant, but flank wear is an increasingfunction of depth of cut. Observations are made on the machined surface, and worn tool by Scanning electron microscope (SEM) toestablish the process. Abrasion was the major wear mechanism found during hard turning within the studied range. The effect of toolwear on surface roughness was also studied. The experimental data were analyzed to predict the optimal range of surface roughness andflank wear. Based on Response surface methodology (RSM), mathematical models were developed for surface roughness (Ra) and flankwear (VB) with 95% confidence level. Finally, under optimum cutting conditions (obtained by response optimization technique), tool lifewas evaluated to perform cost analysis for justifying the economic viability of coated ceramic inserts in hard turning. The estimated machiningcost per part for TiN coated ceramic was found to be lower (Rs. 12.31) because of higher tool life (51 min), which results in thereduction of downtime and increase in savings.
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Machinability investigation and sustainability assessment in FDHT with coated ceramic tool
Asutosh Panda,Sudhansu Ranjan Das,Debabrata Dhupal 국제구조공학회 2020 Steel and Composite Structures, An International J Vol.34 No.5
The paper addresses contribution to the modeling and optimization of major machinability parameters (cutting force, surface roughness, and tool wear) in finish dry hard turning (FDHT) for machinability evaluation of hardened AISI grade die steel D3 with PVD-TiN coated (Al2O3–TiCN) mixed ceramic tool insert. The turning trials are performed based on Taguchi’s L18 orthogonal array design of experiments for the development of regression model as well as adequate model prediction by considering tool approach angle, nose radius, cutting speed, feed rate, and depth of cut as major machining parameters. The models or correlations are developed by employing multiple regression analysis (MRA). In addition, statistical technique (response surface methodology) followed by computational approaches (genetic algorithm and particle swarm optimization) have been employed for multiple response optimization. Thereafter, the effectiveness of proposed three (RSM, GA, PSO) optimization techniques are evaluated by confirmation test and subsequently the best optimization results have been used for estimation of energy consumption which includes savings of carbon footprint towards green machining and for tool life estimation followed by cost analysis to justify the economic feasibility of PVD-TiN coated Al2O3+TiCN mixed ceramic tool in FDHT operation. Finally, estimation of energy savings, economic analysis, and sustainability assessment are performed by employing carbon footprint analysis, Gilbert approach, and Pugh matrix, respectively. Novelty aspects, the present work: (i) contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-60 HRC, (ii) demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing ceramic tool in hard turning processes considering technological, economical and ecological aspects, which are helpful and efficient from industrial point of view, (iii) provides environment friendliness, cleaner production for machining of hardened steels, (iv) helps to improve the desirable machinability characteristics, and (v) serves as a knowledge for the development of a common language for sustainable manufacturing in both research field and industrial practice.
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