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03 Abstract

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12 views

03 Abstract

Uploaded by

zaharizan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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ABSTRACT

Various types of stainless steel were classified on their crystalline

structure with the addition of nickel content. Super duplex stainless steel, is

one of the categorized metals with a high resistance to pitting corrosion and

used in variety of industrial applications. Turning of this material was done in

a medium machining process using CNMG uncoated cemented ceramic

carbide inserts as cutting tool. This turning process was conducted in three

different cutting conditions of dry, wet and gas cooled machining. The

machining process parameters like feed rate, cutting speed and depth of cut

were varied to determine the output response characteristics like surface

roughness, tool flank wear, average cutting zone temperature and cutting

force acted along x axis.

The present research work approaches to optimization of turning

process parameters and the experiments were conducted according to

within the intervals recommended by the tool manufacturer and the

investigation of the present study. Three process parameters at two and three

levels led to total of 18 tests for turning operations. The measured output

responses were analyzed using ANOVA (Analysis of Variance), optimized

using RSM (Response Surface Methodology) and finally verified using

NSGA-II (Non Dominated Sorting Genetic Algorithm). The percentage


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contribution of various machining process parameters and their interactions

on the output responses were presented. A regression analysis was carried out

and RSM models were generated for dry, wet and gas cooled machining.

Gas cooled machining was found to be a best one while compared

with the other methods. Using response surface methodology, the optimized

values of machining process parameters for gas cooled machining are

cutting speed = 100 m/min, feed rate = 0.06 mm/rev and depth of

cut = 0.5303 mm.. Also the predicted values of output responses are surface

roughness = 1.0367 µm, tool flank wear = 0.0641 mm, average cutting zone

temperature = 46.4795 0C and the force acting along x axis is 130.0426 N.

The composite desirability is 0.98036.

The chips formed during all the experiments were collected

separately and a detailed chip morphology study was carried out for all the

three condition. It was found that, gas cooled machining gives the better

machining performance when compared with the dry and wet conditions.

Different machining surface microstructure was identified using SEM

(Scanning Electron Microscope). Gas cooled machining changes the mode of

chip formation and improves the chip tool interaction during machining. It

reduces the chip reduction coefficient and the cutting strain and thereby

reducing the operation time and energy loss which results in increased

production rate.

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