Abstract
This paper presents a multiobjective optimization study of cutting parameters in turning operation for a heat-treated alloy steel material (J-Steel) with Vickers hardness in the range of HV 365–395 using uncoated, unlubricated Tungsten-Carbide tools. The primary aim is to identify proper settings of the cutting parameters (cutting speed, feed rate, and depth of cut) that lead to reasonable compromises between good surface quality and high material removal rate. Thorough exploration of the range of cutting parameters was conducted via a five-level full-factorial experimental matrix of samples and the Pareto trade-off frontier is identified. The trade-off among the objectives was observed to have a “knee” shape, in which certain settings for the cutting parameters can achieve both good surface quality and high material removal rate within certain limits. However, improving one of the objectives beyond these limits can only happen at the expense of a large compromise in the other objective. An alternative approach for identifying the trade-off frontier was also tested via multiobjective implementation of the Efficient Global Optimization (m-EGO) algorithm. The m-EGO algorithm was successful in identifying two points within the good range of the trade-off frontier with 36% fewer experimental samples.
Highlights
Heat-treated alloy steels exhibit many attractive properties, such as wear resistance, high strength, and high thermal stability
Surface roughness was found to increase with increasing feed rate and depth of cut which both result in bigger cut areas that are associated with higher cutting forces and higher friction which lead to poor surface finish
Exploration of the search space was conducted via five-level full factorial, as well as a metamodeling based optimization approach (m-Efficient Global Optimization” (EGO))
Summary
Heat-treated alloy steels exhibit many attractive properties, such as wear resistance, high strength, and high thermal stability. Focus of this research is on optimizing the cutting parameters of CNCturning operations of J-Steel material in order to achieve (i) high-quality surface finish (which translates to product quality) and (ii) high material removal rate (which translates to productivity). The primary control parameters ( termed “design variables” within an optimization framework) in CNC turning are the machining parameters (cutting speed, feed rate, and depth of cut), material, and geometry of the cutting tools and cutting fluids. By selecting a set of standard Tungsten-Carbide insert tools, thereby considering the tooling as a fixed parameter, this study conducts a thorough examination of the three machining parameters and how they relate to the trade-off between surface quality and material removal rate
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