Abstract
Due to their high ductility, high durability, and excellent corrosion resistance, stainless steels are attractive materials for a variety of applications. However, high work hardening, low thermal conductivity, and high built-up edge (BUE) formation make these materials difficult to machine. Rapid tool wear and high cutting forces are the common problems encountered while machining these materials. In the present work, the application of Taguchi optimization methodology has been used to optimize the cutting parameters of the drilling process for machining two stainless steels: austenitic AISI 304 and duplex AISI 2205 under dry conditions. The machining parameters which were chosen to be evaluated in this study are the tool material, cutting speed, and feed rate, while, the response factors to be measured are the tool life (T), cutting force (Fc), and specific cutting energy (ks). Additionally, empirical models were created for predicting the T, Fc and ks using linear regression analysis. The results of this study show that AISI 2205 stainless steel has a shorter tool life, a higher cutting force, and a higher specific cutting energy than AISI 304 stainless steel. In addition, the Taguchi method determined that A3B1C1 and A3B3C1 (A3 = TiN-coated twist drill, B1 = 13 m/min, B3 = 34 m/min, C1 = 0.12 mm/rev) are the optimized combination of levels for the best tool life and the lowest cutting force, respectively. Meanwhile, the optimized combination of levels for all three control factors from the analysis, which provides the lowest specific cutting energy, was found to be A3B1C3 (A3 = TiN-coated twist drill, B1 = 13 m/min, C3 = 0.32 mm/rev) for both stainless steels.
Highlights
Stainless steels are widely used in the chemical, petrochemical, food, and pharmaceutical industries, as well as nuclear energy plants and in stainless appliances [1]
Xavior [10] reported that high work-hardening rate, high built-up edge (BUE) tendency, and low thermal conductivity of AISI 304 stainless steel are responsible for poor surface finish and high tool wear
For a specific range of parameters, the experimental results from the Taguchi method and analysis of variance (ANOVA) analysis, show that the tool life decreases with increasing cutting speed
Summary
Stainless steels are widely used in the chemical, petrochemical, food, and pharmaceutical industries, as well as nuclear energy plants and in stainless appliances [1]. The high ductility of the stainless steel leads to the formation of long continuous chips and to intensive sticking of the workpiece material to the cutting tool surface, which results in enhanced adhesive wear [5]. These conditions promote built-up edge (BUE) formation and tearing off during cutting, which results in cutting edge chipping and cutting force instability. Xavior [10] reported that high work-hardening rate, high BUE tendency, and low thermal conductivity of AISI 304 stainless steel are responsible for poor surface finish and high tool wear. Ciftci [12] performed dry turning experiments on AISI 304 and AISI 316 austenitic stainless steels and the results showed TiC/TiCN/TiN-coated cutting tools produced lower cutting forces than TiCN/TiC/Al2O3-coated tools, because of the lower coefficient of friction of the TiN top coating layer
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