Experimental Investigation and Statistical Evaluation of Optimized Cutting Process Parameters and Cutting Conditions to Minimize Cutting Forces and Shape Deviations in Al6026-T9.

Muhammad Abas,Razaullah Khan,Abdur Rehman Babar,Qazi Salman Khalid,Rashid Nawaz,Bashir Salah,Iftikhar Hussain,Waqas Saleem

doi:10.3390/ma13194327

Abstract

Precise, economical and sustainable cutting operations are highly desirable in the advanced manufacturing environment. For this aim, the present study investigated the influence of cutting parameters (i.e., the cutting speed (c), feed rate (f), depth of cut (d) and positive rake angle (p)) and sustainable cutting conditions (dry and minimum quantity lubricant (MQL)) on cutting forces (i.e., feed force (Ff), tangential forces (Ft), radial force (Fr) and resultant cutting forces (Fc) and shape deviations (i.e., circularity and cylindricity) of a 6026-T9 aluminum alloy. The type of lubricant and insert used are virgin olive oil and uncoated tungsten carbide tool. Turning experiments were performed on a TAKISAWA TC-1 CNC lathe machine and cutting forces were measured with the help of a Kistler 9257B dynamometer. Shape deviations were evaluated by means of a Tesa Micro-Hite 3D DCC 474 coordinate measuring machine (CMM). Experimental runs were planned based on Taguchi mixture orthogonal array design L16. Analysis of variance (ANOVA) was performed to study the statistical significance of cutting parameters. Taguchi based signal to noise (S/N) ratios are applied for optimization of single response, while for optimization of multiple responses Taguchi based signal to noise (S/N) ratios coupled with multi-objective optimization on the basis of ratio analysis (MOORA) and criteria importance through inter-criteria correlation (CRITIC) are employed. ANOVA results revealed that feed rate, followed by a depth of cut, are the most influencing and contributing factors for all components of cutting forces (Ff, Ft, Fr, and Fc) and shape deviations (circularity and cylindricity). The optimized cutting parameters obtained for multi responses are c = 600 m/min, f = 0.1 mm/rev, d = 1 mm and p = 25°, while for cutting conditions, MQL is optimal.

Highlights

Turning of aluminum alloys have gained paramount significance in automobile and aerospace advanced manufacturing
Optimal levels, identified based on Taguchi signal to noise (S/N) ratios coupled with multi-objective optimization based on ratio analysis (MOORA) and criteria correlation (CRITIC) are compared with other methods such as; Taguchi S/N ratios coupled with TOPSIS [49], Taguchi based grey relational analysis [50], composite desirability function [51], and S/N ratios coupled with grey relational analysis [52]
It shows that the responses at optimal levels identified based on the Taguchi S/N ratios coupled with MOORA and CRITIC performed better compared to the initial control parameter settings and optimal levels identified based on other methods, such as the Taguchi grey relational analysis, composite desirability function, S/N ratios coupled with grey relational analysis, and Taguchi

Summary

Introduction

Turning of aluminum alloys have gained paramount significance in automobile and aerospace advanced manufacturing. This is due to its high strength to weight ratio [1,2,3]. Materials 2020, 13, 4327 machining process for the cutting of round objects to the desired shape and size It has the advantages of producing a good quality product, having a lower lead time, customer satisfaction and being economical [1]. While machining such alloys, sustainability of the cutting operation to meet the surface finish, dimensional precision, lower cutting forces, with economic power consumption is highly desirous [1,2]. The appropriate selection of cutting parameters, especially feed rate, cutting speed, and depth of cut are essential to achieve these objectives [1,2]

Methods

Results

Conclusion