International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 05 | May -2017
p-ISSN: 2395-0072
www.irjet.net
Predictive Models and Optimization Techniques In Machining of Hardened Steels: A Case Study M.Rajesh1, K.Ramadevi2, Dr.G.Naga Malleswara Rao3 1Assistant
Professor, Dept of Mechanical Engineering, Gates Institute of Technology, Gooty, Andhra Pradesh, India 2Assistant Professor, Dept of Mechanical Engineering, Gates Institute of Technology, Gooty, Andhra Pradesh, India 3Professor, Dept of Mechanical Engineering, Gates Institute of Technology, Gooty, Andhra Pradesh, India --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Abstract - A unique behavior is on display in hard turning. The process demonstrates high flexibility and an ability to fabricate the geometry of a complex workpiece in a set. It makes a variety of precision components with substantial potential benefits. Many studies have shown aspects and problems that have to be understood and dealt with if the process is to improve. The main factors affecting the reliability of hard turning are surface integrity and tool wear. The prediction of surface roughness, cutting force, and tool life in machining is a challenging task but necessary for proper optimization of the process. This article presents a brief review of the techniques of modeling and optimization that have significant influence in hard turning. Key Words: Machining optimization, Empirical Modeling, Parameters, Techniques, and Predictive Models. 1. INTRODUCTION: In their investigation of the process performance of turning hardened steel, researchers have looked at the effects of coatings, tool materials, and different shapes of inserts. Researchers have also investigated, experimentally, the effect of process parameters (namely residual stresses and white layer formation) on cutting forces and surface integrity. White layers are micro-structural changes observed in the surface layers of machine-hardened steels. Because the hard-turning process boasts several advantages over the grinding process, researchers have paid considerable attention to the machining of hardened steels, working with materials of hardness ranging from 45 to 65 HRC [1]. Some of the advantages include the cutting processing time, and removing cutting fluid[2]. Theseadvantages, however, can only be achieved as the cutting speed (Vc), feed rate (f) and the depth of cut (ap). To better understand hard turning, researchers have studied the effect of these cutting parameters (Vc, f, ap) on tool wear, surface roughness, and surface residual stress distribution in a workpiece [3]. Fig. 1 lays out the main factors to be studied for a better understanding of hard turning.Smith et al. [4] addressed the relationshipbetween surface integrity and fatigue life of hard-bc The results suggest that the effect of white layer outweighs that of surface residual stress on fatigue life. Delijaicov et al. [5] studied the influence of cutting vibrations on the hard turning of AISI 1045 steel with a hardness of 53 HRC. The results provided important implications concerning the surface roughness of hardened steel. Grzesik [6] explored the mechanisms of wear occurring with the mixed ceramic inserts during the hard machining of AISI 5140 having a hardness of 60 HRC. Grzesik [6] considered both microscopic and microstructural aspects, such as abrasion, fracture, plastic flow, adhesive tacking, and material transfer.
Fig. 1. Main factors to consider when working with hard turning
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