دانلود رایگان ترجمه مقاله بهینه سازی زبری سطحی و عمر ابزار جاسازی های کاربید پوششی چندلایه TiAIN/TiN PVD

بهینه سازی زبری سطحی و عمر ابزار جاسازی های کاربید پوششی چندلایه TiAIN/TiN PVD در چرخش نیمه سخت فولاد آلیاژ EN31 سخت شده تحت شرایط برش خشک

Tool Life And Surface Roughness Optimization Of Pvd Tialn/Tin Multilayer Coated Carbide Inserts In Semi Hard Turning Of Hardened En31 Alloy Steel Under Dry Cutting Conditions

ABSTRACT

Tool wear and surface roughness prediction plays a significant role in machining industry for proper planning and control of machining parameters and optimization of cutting conditions. In this paper, Taguchi approach is used to find optimum process parameters for turning while semi hard machining of hardened EN31 alloy steel. A L9 orthogonal array, signal-to-noise ratio and analysis of variance (ANOVA) are applied to study performance characteristics of machining parameters (cutting speed, feed rate and depth of cut) with consideration of surface finish and tool life. The conclusions revealed that the feed rate was the most influential factor on the surface roughness and tool life. Experimental results are provided to illustrate the effectiveness of the proposed approach.

1. INTRODUCTION

The challenge of the mass production firms is focused mainly on the achievement of high quality, in terms of work piece dimensional accuracy, surface finish, high production rate, less wear on the cutting tools. As technological development in manufacturing industry growing, companies are switching to coated grades of carbide tools from regular carbide grades for machining operations of hardened steels[10]. The last decade has been dominated by physical vapor deposited (PVD) coated carbide tools. Nowadays, thin advanced multilayer coatings deposited by physical vapor deposition (PVD) technique on tungsten carbide substrate material are used in order to increase wear resistance and reduce insert chipping. Tool wear, cutting force, surface roughness and cutting power are relative responses. Tool wear results in changes in tool geometry that affect cutting forces, cutting power, and surface finish [3]. It is the main factor that determines the economics in metal cutting. A lower rate of tool wear means increased tool life, better surface finish, reduced tooling cost and lower cost of production. In case of PVD TiAlN coating, the improvement in the cutting performance is due to the oxidation resistance of TiAlN properties at higher temperature [8]. High wear resistance even at high temperatures is the outstanding property of TiAlN [10], a characteristic that makes this coating appropriate to cut abrasive work piece material such as cast iron, aluminium silicon alloys and composite materials at high speeds.

5. CONCLUSIONS

From the analysis of the results in the turning process using the conceptual signal-to-noise (S/N) ratio approach, analysis of variance (ANOVA), regression analysis and Taguchi’s optimization method, the following can be concluded from the present study: • Statistically designed experiments based on Taguchi methods were performed using L9 orthogonal arrays to analyse the tool wear and surface roughness as response variables. Conceptual S/N ratio and ANOVA approaches for data analysis drew similar conclusions. • Maximum Tool Life is obtained at a cutting speed of 180 m/min, a moderate feed rate of 0.10 mm/revolutions and a depth of cut of 0.7 mm. • Highest surface finish (lowest Ra) is obtained at a cutting speed of 180 m/min, a moderate feed rate of 0.10 mm/revolutions and a depth of cut of 0.9mm. • The improvement of the surface roughness from the initial machining parameters to the optimal machining parameters is about 280%, whereas the tool life is improved by 161%. • Interaction plots for Tool life and surface roughness show that speed and feed interactions affect the most to the machining performance of TiAlN coated carbide cutting tool inserts in turning hardened EN31 alloy steel in dry conditions. • The results of ANOVA for Tool life show that feed rate is most significant parameter (contribution 59%) which affects the Tool life than other cutting parameters. The cutting speed is the next contributing factor whose contribution is 35.86 % and lowest contribution from depth of cut which is 2.39 %. • The results of ANOVA for surface roughness show that feed rate is most significant parameter (contribution 87 %) which affects the Tool life than other cutting parameters. The cutting speed and DOC are least significant parameters.

بهینه سازی زبری سطحی و عمر ابزار جاسازی های کاربید پوششی چندلایه TiAIN/TiN PVD در چرخش نیمه سخت فولاد آلیاژ EN31 سخت شده تحت شرایط برش خشک

Tool Life And Surface Roughness Optimization Of Pvd Tialn/Tin Multilayer Coated Carbide Inserts In Semi Hard Turning Of Hardened En31 Alloy Steel Under Dry Cutting Conditions