Abstract
In this paper, the effects of multi-radii geometry of inserts on material removal rate (MRR) and surface integrity are studied. An innovative model was developed based on the Monte Carlo method to predict the MRR during turning with different tool nose geometries and the maximum prediction error was controlled within 2.7%. The results demonstrated that both roughness heights and irregularities of the machined surfaces were half reduced by using multi-radii wiper inserts compared to those obtained by conventional inserts. Feed rate was optimized as 0.4 mm/rev in turning with wiper inserts. As a result, surface integrity improves by 41.45% and energy consumption reduces by 4.25%. The corrosion resistance of the AISI 1045 steel was improved by the laser cladding and high feed rate turning process chain. Turning with feed rate of 0.4 mm/rev provided the highest corrosion resistance. The premise of using multi-radii wiper inserts for higher MRR while maintaining good surface integrity was realized. Such conditions determined finishing process of remanufactured parts and the obtained minimization of specific cutting energy enabled sustainable manufacturing process.
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