Determining of the Optimal Turning Parameters Using the Response Surface Methodology in Powder Metallurgical Tool Steel

Year 2016, , 272 - 280, 31.05.2016

Alaattin Kaçal , Ferhat Yıldırım

https://doi.org/10.31202/ecjse.264190

Abstract

The influence of cutting parameters on the surface roughness in turning of PMD 23 powder metallurgical (PM) steel was investigated in this work.  With three different cutting speeds, feed rates, depth of cuts and two different types tool geometry of carbide inserts were determined as cutting parameters Taguchi L₁₈ orthogonal array was used to design of experiment. In order to find out the effect of cutting parameters on the average surface roughness (R_a) and prediction model of R_a, response surface method (RSM) was used. The results obtained by RSM revealed that the feed rate was dominant parameter on changes in R_a. The developed predicting model of R_a can be effectively used on PMD 23 PM steel within 95% confidence intervals ranges according to the experimental parameters.

Keywords

Hard Turning, Surface roughness, Response surface method

Toz Metalurjisi Takım Çeliklerinde Cevap Yüzey Metodu Kullanarak Optimum Tornalama Parametrelerinin Belirlenmesi

Abstract

Bu çalışmada PMD 23 Toz Metalürjisi (TM) çeliğin tornalanmasında kesme parametrelerinin yüzey pürüzlülüğü üzerindeki etkileri araştırılmıştır. Üç farklı kesme hızı, ilerleme oranı, kesme derinliği ve iki farklı takım geometrili karbür uç tipi kesme parametreleri olarak belirlenmiştir. Deney tasarımı için Taguchi L18ortogonal dizi kullanılmıştır. Kesme parametrelerinin ortalama yüzey pürüzlülüğü (Ra) ve Ra 'nın tahmin modeli üzerindeki etkisini belirlemek için cevap yüzey yöntemi (RSM) kullanılmıştır. RSM ile elde edilen sonuçlar, ilerleme oranının Ra’nın değişimi üzerinde etkin bir parametre olduğunu ortaya çıkarmıştır. Ra için geliştirilen tahmin modeli, deneysel parametrelere göre PMD 23 PM çelik için etkin bir şekilde %95 güven aralığı içinde kullanılabilir. Minimum yüzey pürüzlülüğü için düşük ilerleme oranı ve yüksek kesme hızı ile düşük kesme derinliği parametrelerinin uygun olduğu anlaşılmıştır

Keywords

Sert tornalama, Yüzey pürüzlülüğü, Cevap yüzey metodu

References

• H. Aouici, M. A. Yallese, K. Chaoui, T. Mabrouki, and J. F. Rigal, "Analysis of surface roughness and cutting force components in hard turning with CBN tool: Prediction model and cutting conditions optimization," Measurement, vol. 45, pp. 344-353, Apr 2012.
• I. Asilturk and H. Akkus, "Determining the effect of cutting parameters on surface roughness in hard turning using the Taguchi method," Measurement, vol. 44, pp. 1697-1704, Nov 2011.
• M. W. Azizi, S. Belhadi, M. A. Yallese, T. Mabrouki, and J. F. Rigal, "Surface roughness and cutting forces modeling for optimization of machining condition in finish hard turning of AISI 52100 steel," Journal of Mechanical Science and Technology, vol. 26, pp. 4105-4114, Dec 2012.
• G. Bartarya and S. K. Choudhury, "Effect of cutting parameters on cutting force and surface roughness during finish hard turning AISI52100 grade steel," presented at the Fifth Cirp Conference on High Performance Cutting 2012, Amsterdam, 2012.
• E. Bingul and A. Kacal, "Hard Turning of Powder Metallurgical Cold Work Tool Steel Tempered in Different Tempering Temperature," Journal Of Scientific & Industrial Research, vol. 72, pp. 498-505, 2013.
• M. P. Grover, Fundementals of modern manufacturing New York: Wiley, 1999.
• W. Grzesik, "Influence of tool wear on surface roughness in hard turning using differently shaped ceramic tools," Wear, vol. 265, pp. 327-335, Jul 2008.
• M. Gunay and E. Yucel, "Application of Taguchi method for determining optimum surface roughness in turning of high-alloy white cast iron," Measurement, vol. 46, pp. 913-919, Feb 2013.
• Z. Hessainia, A. Belbah, M. A. Yallese, T. Mabrouki, and J. F. Rigal, "On the prediction of surface roughness in the hard turning based on cutting parameters and tool vibrations," Measurement, vol. 46, pp. 1671-1681, Jun 2013.
• A. Kacal and M. Gulesin, "Determination of optimal cutting conditions in finish turning of austempered ductile iron using Taguchi design method," Journal of Scientific & Industrial Research, vol. 70, pp. 278-283, Apr 2011.
• A. Kacal and F. Yildirim, "Application of grey relational analysis in high-speed machining of hardened AISI D6 steel," Proceedings of the Institution of Mechanical Engineers Part C-Journal of Mechanical Engineering Science, vol. 227, pp. 1566-1576, Jul 2013.
• S. S. Kalpakjian, S. R., Manufacturing engineering and technology fourth edition. New Jersey: Prentice Hall, 2001.
• G. Poulachon, B. P. Bandyopadhyay, I. S. Jawahir, S. Pheulpin, and E. Seguin, "Wear behavior of CBN tools while turning various hardened steels," Wear, vol. 256, pp. 302-310, Feb 2004.
• D. Singh and P. V. Rao, "A surface roughness prediction model for hard turning process," International Journal of Advanced Manufacturing Technology, vol. 32, pp. 1115-1124, May 2007.
• R. Suresh, S. Basavarajappa, V. N. Gaitonde, and G. L. Samuel, "Machinability investigations on hardened AISI 4340 steel using coated carbide insert," International Journal of Refractory Metals & Hard Materials, vol. 33, pp. 75-86, Jul 2012.
• T. Aksoy, "Investigation of cutting tool performance and chip geometry in machining PMD 23 steel produced by powder metallurgy," M.Sc M.Sc, Institute of Science, Investigation of cutting tool performance and chip geometry in machining PMD 23 steel produced by powder metallurgy, Kırıkkale, 2009.
• B. K. Bakır, Mustafa Basmacı, Gültekin Girit, Oğuz, "Frezelemede kesici takım çapı, ağız sayisi ve talaş açısının yüzey pürüzlülüğü ve kesici takım sehimlerine etkileri," in 3. Ulusal Tasarım İmalat ve Analiz Kongresi, Balıkesir-Türkiye, 29-30 Kasım 2012.
• J. P. Davim and L. Figueira, "Machinability evaluation in hard turning of cold work tool steel (D2) with ceramic tools using statistical techniques," Materials & Design, vol. 28, pp. 1186-1191, 2007.
• D. I. Lalwani, N. K. Mehta, and P. K. Jain, "Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel," Journal of Materials Processing Technology, vol. 206, pp. 167-179, Sep 2008.
• S. A. Neseli, Ilhan Yaldız, Suleyman Saglam, Hacı, "Tornalama işleminde cevap yüzey metodu ile kesme kuvvetlerinin kesme parametrelerine bağlı olarak modellenmesi," in 3. Ulusal Talaşlı İmalat Sempozyumu, 04-05 Ekim 2012, pp. 442-455.
• R. G. Sood, C Malkin,S, "Turning of Hardened Steels," Journal of Manufacturing Processes, vol. 2, pp. 187-193, 2000.
• S. Neseli, S. Yaldiz, and E. Turkes, "Optimization of tool geometry parameters for turning operations based on the response surface methodology," Measurement, vol. 44, pp. 580-587, Mar 2011.
• M. S. Dogra, V. S. Durejac, J, "Effect of tool geometry variation on finish turning – A Review," Journal of Engineering Science and Technology Review, vol. 4, pp. 1-13, 2011.
• H.-J. Choi, "DOE and Optimization," in Response Surface Methodology, ed Chung-Ang University School of Mechanical Engineering.
• M. Gunay, A. Kacal, and Y. Turgut, "Optimization of machining parameters in milling of ti-6al-4v alloy using taguchi method," e-Journal of New World Sciences Academy, vol. 6, pp. 428-440, 2011.