Design optimization for analysis of surface integrity and chip morphology in hard turning

다국어 초록 (Multilingual Abstract)

The present work addresses the surface integrity and chip morphology in finish hard turning of AISI D3 steel under nanofluid assisted minimum quantity lubrication (NFMQL) condition. The surface integrity aspects include microhardness, residual stress, white layer formation, machined surface morphology, and surface roughness. This experimental investigation aims to explore the feasibility of low-cost multilayer (TiCN/Al2O3/TiN) coated carbide tool in hard machining applications and to assess the propitious role of minimum quantity lubrication using graphene nanoparticles enriched eco-friendly radiator coolant based nano-cutting fluid for machinability improvement of hardened steel. Combined approach of central composite design (CCD) - analysis of variance (ANOVA), desirability function analysis, and response surface methodology (RSM) have been subsequently employed for experimental investigation, predictive modelling and optimization of surface roughness. With a motivational philosophy of “Go Green-Think Green-Act Green”, the work also deals with economic analysis, and sustainability assessment under environmental-friendly NFMQL condition. Results showed that machining with nanofluid-MQL provided an effective cooling-lubrication strategy, safer and cleaner production, environmental friendliness and assisted to improve sustainability.

참고문헌 (Reference)

1 More, A.S, "Tool wear and machining performance of CBN-TiN coated carbide inserts and PCBN compact inserts in turning AISI 4340 hardened steel" 180 (180): 253-262, 2006

2 Khan, A. M., "Sustainability-based performance evaluation of hybrid nanofluid assisted machining" 257 : 120541-, 2020

3 Abbas, A. T., "Sustainability assessment associated with surface roughness and power consumption characteristics in nanofluid MQL-assisted turning of AISI 1045 steel" 105 : 1311-1327, 2019

4 Das, S. R., "Surface roughness analysis of hardened steel using TiN coated ceramic inserts" 17 (17): 22-38, 2015

5 Panda, A., "Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation" 1 (1): 237-249, 2017

6 Das, A., "Statistical analysis of different machining characteristics of EN-24 alloy steel during dry hard turning with multilayer coated cermet inserts" 134 : 123-141, 2018

7 Suresh, R., "State-of-the-art research in machinability of hardened steels" 227 (227): 191-209, 2013

8 Mia, M., "Six sigma optimization of multiple machining characteristics in hard turning under dry, flood, MQL and solid lubrication" 1 (1): 1-12, 2020

9 Mia, M., "Prediction of surface roughness in hard turning under high pressure coolant using Artificial Neural Network" 92 : 464-474, 2016

10 Mia, M., "Prediction and optimization of surface roughness in minimum quantity coolant lubrication applied turning of high hardness steel" 118 : 43-51, 2018

11 Mia, M., "Prediction and optimization by using SVR, RSM and GA in hard turning of tempered AISI 1060 steel under effective cooling condition" 31 : 2349-2370, 2019

12 Asiltürk, İ., "Predicting surface roughness of hardened AISI 1040 based on cutting parameters using neural networks and multiple regression" 63 (63): 249-257, 2012

13 Bensouilah, H., "Performance of coated and uncoated mixed ceramic tools in hard turning process" 82 : 1-18, 2016

14 Rashid, W. B., "Parametric design optimization of hard turning of AISI 4340 steel (69 HRC)" 82 (82): 451-462, 2015

15 Shihab, S. K., "Optimization of surface integrity in dry hard turning using RSM" 39 (39): 1035-1053, 2014

16 Hessainia, Z., "On the prediction of surface roughness in the hard turning based on cutting parameters and tool vibrations" 46 (46): 1671-1681, 2013

17 Saini, S., "Modelling the effects of cutting parameters on residual stresses in hard turning of AISI H11 tool steel" 65 (65): 667-678, 2012

18 Mia, M., "Modeling of Surface Roughness Using RSM, FL and SA in Dry Hard Turning" 43 (43): 1125-1136, 2017

19 Shaw, M. C., "Metal Cutting Principles" Oxford University Press 2005

20 Kumar, R., "Measurement and machinability study under environmentally conscious spray impingement cooling assisted machining" 135 : 913-927, 2018

21 Davim, J. P., "Machining of Hard Materials" Springer-Verlag London 2011

22 Davim, J. P., "Machining Fundamentals and Recent Advances" Springer-Verlag London 2019

23 Suresh, R., "Machinability investigations on hardened AISI 4340 steel using coated carbide insert" 33 : 75-86, 2012

24 Gaitonde, V. N., "Machinability investigations in hard turning of AISI D2 cold work tool steel with conventional and wiper ceramic inserts" 27 (27): 754-763, 2009

25 Asutosh Panda, "Machinability investigation and sustainability assessment in FDHT with coated ceramic tool" 국제구조공학회 34 (34): 681-698, 2020

26 Davim, J. P., "Machinability evaluation in hard turning of cold work tool steel(D2)with ceramic tools using statistical techniques" 28 (28): 1186-1191, 2007

27 Panda, A., "Investigations on surface quality characteristics with multi-response parametric optimization and correlations" 55 (55): 1625-1633, 2016

28 Nouioua, M., "Investigation of the performance of the MQL, dry, and wet turning by response surface methodology (RSM) and artificial neural network (ANN)" 93 (93): 2485-2504, 2017

29 Shihab, S. K., "Investigation of surface integrity during wet turning of hard alloy steel" 16 (16): 22-37, 2014

30 Sharma, P., "Investigation of effects of nanofluids on turning of AISI D2 steel using minimum quantity lubrication" 108 : 72-79, 2015

31 Kumar, P., "Influence of Different Grades of CBN Inserts on Cutting Force and Surface Roughness of AISI H13 Die Tool Steel during Hard Turning Operation" 12 (12): 177-, 2019

32 Chinchanikar, S., "Hard turning using HiPIMS-coated carbide tools : Wear behavior under dry and minimum quantity lubrication(MQL)" 55 : 536-548, 2014

33 Mohamed Baccar Mhamdi, "Experimental study of the chip morphology in turning hardened AISI D2 steel" 대한기계학회 27 (27): 3451-3461, 2013

34 Sahoo, A. K., "Experimental investigations on machinability aspects in finish hard turning of AISI 4340 steel using uncoated and multilayer coated carbide inserts" 45 (45): 2153-2165, 2012

35 Tang, L., "Experimental investigation of surface integrity in finish dry hard turning of hardened tool steel at different hardness levels" 77 (77): 1655-1669, 2014

36 Das, S. R., "Experimental investigation into machinability of hardened AISI 4140 steel using TiN coated ceramic tool" 62 : 108-126, 2015

37 Naresh Babu, M., "Evaluation of graphene based nano fluids with minimum quantity lubrication in turning of AISI D3 steel" 1 (1): 1-11, 2019

38 Khan, A. M., "Energy-Based Cost Integrated Modelling and Sustainability Assessment of Al-GnP Hybrid Nanofluid Assisted Turning of AISI52100 Steel" 257 : 120502-, 2020

39 Ouahid Keblouti, "Effects of coating material and cutting parameters on the surface roughness and cutting forces in dry turning of AISI 52100 steel" 국제구조공학회 61 (61): 519-526, 2017

40 Mia, M., "Effect of time-controlled MQL pulsing on surface roughness in hard turning by statistical analysis and artificial neural network" 91 (91): 3211-3223, 2017

41 Elmunafi, M. H. S., "Effect of cutting speed and feed in turning hardened stainless steel using coated carbide cutting tool under minimum quantity lubrication using castor oil" 7 (7): 1-7, 2015

42 Xiao, Z., "Effect of cutting parameters on surface roughness using orthogonal array in hard turning of AISI 1045 steel with YT5 tool" 93 (93): 273-282, 2016

43 Asiltürk, İ., "Determining the effect of cutting parameters on surface roughness in hard turning using the Taguchi method" 44 : 1697-1704, 2011

44 Costa, N. R., "Desirability function approach : A review and performance evaluation in adverse conditions" 107 (107): 234-244, 2011

45 Aouici, H., "Comparison on various machinability aspects between mixed and reinforced ceramics when machining hardened steels" 20 : 109-, 2019

46 Fnides, B., "Comparison between mixed ceramic and reinforced ceramic tools in terms of cutting force components modelling and optimization when machining hardened steel AISI 4140(60 HRC)" 16 (16): 609-, 2015

47 Kumar, R., "Comparative investigation towards machinability improvement in hard turning using coated and uncoated carbide inserts : part I experimental investigation" 6 (6): 52-70, 2018

48 Elbah, M., "Comparative assessment of wiper and conventional ceramic tools on surface roughness in hard turning AISI 4140 steel" 46 (46): 3041-3056, 2013

49 Elbah, M., "Comparative assessment of machining environments(dry, wet and MQL)in hard turning of AISI 4140 steel with CC6050 tools" 105 : 2581-2597, 2019

50 Aouici, H., "Comparative assessment of coated and uncoated ceramic tools on cutting force components and tool wear in hard turning of AISI H11 steel using Taguchi plan and RMS" 42 (42): 2157-2170, 2017

51 Tang, L., "Chip formation mechanism in dry hard high-speed orthogonal turning of hardened AISI D2 tool steel with different hardness levels" 93 (93): 2341-2356, 2017

52 Panday, G., "Assessing near-dry lubrication(35 ml/h)performance in hard turning process of hardened(48 HRC)AISI 1060 carbon steel" 99 : 2045-2057, 2018

53 Khan, Z. A., "Analysis of chip morphology in dry hard turning of AISI 52100 alloy steel using RSM" 17 (17): 481-506, 2015

54 Gaitonde, V. N., "Analysis of Machinability During Hard Turning of Cold Work Tool Steel(Type : AISI D2)" 24 (24): 1373-1382, 2009

55 Mia, M., "An approach to cleaner production for machining hardened steel using different cooling-lubrication conditions" 187 : 1069-1081, 2018

56 Das, A., "A Comparison of Machinability in Hard Turning of EN-24 Alloy Steel Under Mist Cooled and Dry Cutting Environments with a Coated Cermet Tool" 19 : 115-130, 2018