Optimization and analysis of cutting parameters using cryogenic media in machining of high strength alloy steel

In this research, liquid Argon is used as a cryogenic media to optimize the cutting parameters for evaluation of tool flank wear width of Tungsten Carbide Insert (CNMG 120404-WF 4215) while turning high strength alloy steel. Robust design concept of Taguchi L9 (34) method is applied to determine the optimum conditions. This analysis revealed is revealed that cryogenic impact is more significant in reduction of the tool flank wear

Statistical analysis of the effect of machining parameters on fatigue life of aerospace grade aluminum alloy (AL 6082T6)

In this research work, aerospace grade aluminium alloy (Al 6082-T6) was analysed for the effect of cutting parameters on the fatigue life of the machined samples and optimization of cutting parameters for response factor. Different combinations of machining parameters were selected according to the ISO 3685 for sample preparation. Fatigue life of the samples was the response variable under investigation. Specimens for the rotating bending fatigue test were prepared according to the BS ISO 1143:2010 standards. The cutting inserts were selected from Sandvik Coromant catalogue recommended for machining of Al 6082-T6 alloy. A Designed of Experiment (DoE) with full factorial design was employed and a total of 81 experiments were performed for combination of cutting parameters. Fatigue life of the samples was observed to decreases with increasing feed rate, which is attributed to the compressive residual stresses at the surface of the samples. However, fatigue life increased with higher cutting speed and Depth of Cut (DoC)

Energy consumption analysis in turning Ti-6Al-4V alloy.

One of the major concerns in manufacturing industries include the amount of energy consumed during machining processes. Therefore, the study of the specific energy during machining must be analyzed in relation to the process parameters (feed rate, speed and depth of cut). This work demonstrates the analysis of specific cutting energy (SCE) and cutting power during titanium alloys machining under dry conditions. Turning experiments with uncoated carbide inserts were performed applying Taguchi Design of Experiments technique and analyzed the effect of speed, feed and depth of cut during turning Ti-6Al-4V titanium alloys. ANOVA was done to find out the influence of the machining parameters on energy consumption. The outcome of this analysis indicates that feed rate is the highly dominant factor responsible for the SCE of a machine tool, whereas, cutting speed was found as the influential factor affecting the power during the machining process. The environmental and economic performance for a machining process may be significantly improved by reducing energy consumption using appropriate machining conditions

Development and analysis of tool wear and energy consumption maps for turning of titanium alloy (Ti6Al4V).

Machine tools are the main source of electric power consumption in industrial operations. Thus, in manufacturing, energy-efficient and cleaner production methods are preferred to mitigate production costs. Titanium alloys are known for their poor machinability and are generally characterized by low tool life, high energy consumption and poor surface quality due to its unique physical and mechanical properties. This research aims to evaluate the tool wear rate (R) and the specific cutting energy (SCE) at varying cutting conditions by developing tool wear and energy maps using unified cutting tests. Uncoated H13A tools were used during single-point turning of Ti-6Al-4V alloy by employing Full Factorial Design of Experiments. Based on experimental data, comprehensive process maps were developed for monitoring wear and energy data. These maps showed regions of (low moderate and high) wear and specific energy consumption. It was observed that while machining Ti-6Al-4V alloy the recommended cutting condition (V=100 m/min and f =0.16 mm/rev) enhances the tool life and reduces energy consumption together with high material removal rate. It was also deduced that instead of low speed, using a higher speed of 125 m/min will increase MRR by 127 % and SCE by 16 %, which is more feasible in a production environment. From tool-chip contact length and chip morphology analysis, a strong correlation indicated the reason behind the occurrence of various zones on the maps. It has been found that high wear and energy zone occurred due to the larger contact length and higher chip compression ratio when machining at high speed. The developed maps can be used to help the manufacturers achieve the economic and energy-efficient goal of machining

Numerical and experimental investigation of the effect of process parameters on sheet deformation during the electromagnetic forming of AA6061-T6 alloy.

Electromagnetic forming is a high-speed sheet metal forming technique to form metallic sheets by applying magnetic forces. In comparison to the conventional sheet metal forming process, electromagnetic forming is a process with an extremely high velocity and strain rate, which can be effectively used for the forming of certain difficult-to-form metals. During electromagnetic forming, it is important to recognise the effects of process parameters on the deformation and sheet thickness variation of the sheet metal. This research focuses on the development of a numerical model for aluminium alloy (AA6061-T6) to analyse the effects of three process parameters, namely voltage, sheet thickness and number turns of the coils, on the deformation and thickness variation of the sheet. A two-dimensional fully coupled finite-element (FE) model consisting of an electrical circuit, magnetic field and solid mechanics was developed and used to determine the effect of changing magnetic flux and system inductance on sheet deformation. Experiment validation of the results was performed on a 28 KJ electromagnetic forming system. The Taguchi orthogonal array approach was used for the design of experiments using the three input parameters (voltage, sheet thickness and number of turns of the coil). The maximum error between numerical and experimental values for sheet thickness variation was observed to be 4.9 %. Analysis of variance (ANOVA) was performed on the experimental results. Applied voltage and sheet thickness were the significant parameters, while the number of turns of the coil had an insignificant effect on sheet deformation. The contribution ratio of voltage and sheet thickness was 46.21 % and 45.12 % respectively. The sheet deformation from simulations was found to be in good agreement with the experimental results

Multi-objective optimization for sustainable turning Ti6Al4V alloy using grey relational analysis (GRA) based on analytic hierarchy process (AHP).

Sustainable machining necessitates energy-efficient processes, longer tool lifespan, and greater surface integrity of the products in modern manufacturing. However, when considering Ti6Al4V alloy, these objectives turn out to be difficult to achieve as titanium alloys pose serious machinability challenges, especially at elevated temperatures. In this research, we investigate the optimal machining parameters required for turning of Ti6Al4V alloy. Turning experiments were performed to optimize four response parameters, i.e., specific cutting energy (SCE), wear rate (R), surface roughness (Ra), and material removal rate (MRR) with uncoated H13 carbide inserts in the dry cutting environment. Grey relational analysis (GRA) combined with the analytic hierarchy process (AHP) was performed to develop a multi-objective function. Response surface optimization was used to optimize the developed multi-objective function and determine the optimal cutting condition. As per the ANOVA, the interaction of feed rate and cutting speed (f × V) was found to be the most significant factor influencing the grey relational grade (GRG) of the multi-objective function. The optimized machining conditions increased the MRR and tool life by 34% and 7%, whereas, reducing the specific cutting energy and surface roughness by 6% and 2% respectively. Using Taguchi-based GRA by analytic hierarchy process (AHP) weights method, the benefits of high-speed machining Ti6Al4V through multi-response optimization were achieved

Tool wear progression and its effect on energy consumption in turning of titanium alloy (Ti-6Al-4V).

To achieve greater productivity, titanium alloy requires cutting at higher speeds (above 100 m min−1) that affects the tool life and energy consumption during the machining process. This research work correlates the wear progression and Specific Cutting Energy (SCE) in turning Ti-6Al-4V alloy using H13 tools (uncoated carbide) in dry conditions from low to high cutting speeds. Cutting condition employed in this study were selected from published wear map developed for titanium (Ti-6Al-4V alloy) with the same tool. Flank wear growth of the tool has been investigated at different length of cuts in correlation with the SCE under different cutting conditions. The useful tool life was found to be shorter at high-speed machining conditions, thus the end of useful tool life criteria (ISO 3685) was reached at a much shorter length of cuts as compared to low-speed machining conditions. The cutting conditions corresponding to high wear rate also resulted in high SCE. Finally, SCE and wear have been related by a linear relationship that can be used to monitor wear and/or SCE utilization during machining. The results help in the selection of appropriate cutting conditions that will enhance the tool life and minimize SCE consumption during machining titanium alloy

Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions.

Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of hard-to-cut materials has always posed a challenge due to increased tool wear and energy loss. Cryogenics have emerged as an effective means to improve sustainability in the recent past. In the present research the use of cooling conditions has been investigated as an input variable to analyze its effect on tool wear, specific cutting energy and surface roughness in combination with other input machining parameters of feed rate, cutting speed and depth of cut. Experimental design was based on Taguchi design of experiment. Analysis of Variance (ANOVA) was carried out to ascertain the contribution ratio of each input. Results showed the positive effect of coolant usage, particularly cryogenic, on process responses. Tool wear was improved by 33% whereas specific cutting energy and surface roughness were improved by 10% and 9% respectively by adapting the optimum machining conditions

Multi-objective optimization of turning titanium-based alloy Ti-6Al-4V under dry, wet, and cryogenic conditions using gray relational analysis (GRA).

In modern manufacturing industries, the importance of multi-objective optimization cannot be overemphasized particularly when the desired responses are differing in nature towards each other. With the emergence of new technologies, the need to achieve overall efficiency in terms of energy, output, and tooling is on the rise. Resultantly, endeavor is to make the machining process sustainable, productive, and efficient simultaneously. In this research, the effects of machining parameters (feed, cutting speed, depth of cut, and cutting condition including dry, wet, and cryogenic) were analyzed. Since sustainable production demands a balance between production quality and energy consumption, therefore, response parameters including specific cutting energy, tool wear, surface roughness, and material removal rate were considered. Taguchi-gray integrated approach was adopted in this study. Multi-objective function was developed using gray relational methodology, and its regression analysis was conducted. Response surface optimization was carried out to optimize the formulated multi-objective function and derive the optimum machining parameters. Concurrent responses were optimized with best-suited values of input parameters to make the most out of the machining process. Analysis of variance results showed that feed is the most effective parameter followed by cutting condition in terms of overall contribution in multi-objective function. The proposed optimum parameters resulted in improvement of tool wear and surface roughness by 30% and 22%, respectively, whereas specific cutting energy was reduced by 4%

Development of a STEP-compliant design and manufacturing framework for discrete sheet metal bend parts

Metal sheets have the ability to be formed into nonstandard sizes and sections. Displacement-controlled computer numerical control press brakes are used for three-dimensional sheet metal forming. Although the subject of vendor neutral computer-aided technologies (computer-aided design, computer-aided process planning and computer-aided manufacturing) is widely researched for machined parts, research in the field of sheet metal parts is very sparse. Blank development from three-dimensional computer-aided design model depends on the bending tools geometry and metal sheet properties. Furthermore, generation and propagation of bending errors depend on individual bend sequences. Bend sequence planning is carried out to minimize bending errors, keeping in view the available tooling geometry and the sheet material properties’ variation. Research reported in this article attempts to develop a STEP-compliant, vendor neutral design and manufacturing framework for discrete sheet metal bend parts to provide a capability of bidirectional communication between design and manufacturing cycles. Proposed framework will facilitate the use of design information downstream at the manufacturing stage in the form of bending workplan, bending workingsteps and a feedback mechanism to the upstage product designer. In order to realize this vendor neutral framework, STEP (ISO 10303), AP203, AP207, and AP219 along with STEP-NC (ISO14649) have been used to provide a basis of vendor neutral data modeling.N/