Investigation of the Effect of Cutting Parameters on Surface Roughness in Turning of AISI 420 Steel Using Finite Element Analysis and Taguchi Experimental Design

Year 2023, Volume: 6 Issue: 2, 232 - 241, 31.12.2023

Barış Özlü Levent Uğur Aytaç Yıldız

https://doi.org/10.55117/bufbd.1388187

Abstract

AISI 420 martensitic stainless steel is frequently used in the machinery, petroleum and petrochemical industries, food and food production facilities, automotive industry, steam turbine blades and the production of medical instruments due to its high corrosion resistance. Turning of this type of steel is an important process, especially in the production of parts with high surface quality. The surface quality of the final product is a critical factor that determines the overall quality of the product and the efficiency of the processing process. Therefore, in this study, the effects of cutting parameters (cutting speed, feed rate and depth of cut) on absolute surface roughness value (Rz) in turning AISI 420 martensitic stainless steel were investigated using the finite element method and Taguchi experimental design. Machining experiments were carried out in the ThirdWave AdvantEdge program, which is a finite element analysis software. As a result of the finite element analysis of the study, it was determined that the Rz value decreased by increasing the cutting speed, and the Rz values increased by increasing the feed rate and depth of cut. As a result of the statistical analysis obtained as a result of the Taguchi experimental design, the optimum cutting parameters were determined as 0.1 mm/rev feed amount, 230 m/min cutting speed and 0.9 mm cutting depth. Additionally, it has been determined that the most important cutting parameter affecting Rz is the feed rate.

Keywords

AISI 420, Turning, Surface roughness, Finite Element Analysis, Taguchi

AISI 420 Çeliğinin Tornalamasında Kesme Parametrelerinin Yüzey Pürüzlülüğüne Etkisinin Sonlu Elemanlar Analizi ve Taguchi Deney Tasarımıyla İncelenmesi

Abstract

AISI 420 martensitik paslanmaz çelik, yüksek korozyon direnci nedeniyle makine, petrol ve petro kimya endüstrilerinde, gıda ve gıda üretim tesislerinde, otomotiv sanayinde, buhar türbin kanatlarında ve tıbbi aletlerin üretiminde sıklıkla kullanılmaktadır. Bu çelik türünün tornalanması, özellikle yüksek yüzey kalitesine sahip parçaların üretiminde önemli bir prosestir. Son ürünün yüzey kalitesi, ürünün genel kalitesini ve işleme sürecinin verimliliğini belirleyen kritik bir faktördür. Bu nedenle bu çalışmada sonlu elemanlar yöntemi ve Taguchi deney tasarımı kullanılarak AISI 420 martensitik paslanmaz çeliğin tornalanmasında kesme parametrelerinin (kesme hızı, ilerleme miktarı ve kesme derinliği) mutlak yüzey pürüzlülük değerine (Rz) etkileri araştırılmıştır. İşleme deneyleri sonlu elemanlar analizi yazılımı olan ThirdWave AdvantEdge programında yapılmıştır. Çalışmanın sonlu elemanlar analizi sonucunda kesme hızının artırılması ile Rz değerinin azaldığı, ilerleme miktarının ve kesme derinliğinin artırılması ile Rz değerlerinin arttığı tespit edilmiştir. Yapılan Taguchi deney tasarımı sonucu elde edilen istatiksel analizler sonucu optimum kesme parametreleri 0.1 mm/rev ilerleme miktarı, 230 m/min kesme hızı ve 0.9 mm kesme derinliği olarak belirlenmiştir. Ayrıca, Rz’ye etki eden en önemli kesme parametresinin ilerleme miktarı olduğu tespit edilmiştir.

Keywords

AISI 420, Tornalama, Yüzey Pürüzlülüğü, Sonlu Elemanlar Analizi, Taguchi

References

• [1] W. F. Smith, and J. Hashemi, Foundations of materials science and engineering. Mcgraw-Hill Publishing, 2006.
• [2] D. Palanisamy, A. Devaraju, D. Arulkirubakaran, and N. Manikandan, "Experimental investigation on surface integrity during machining of AISI 420 steel with tungsten carbide insert," Materials Today: Proceedings, vol. 22, pp. 992-997, 2020.
• [3] C. Moganapriya, R. Rajasekar, T. Mohanraj, V. Gobinath, P. S. Kumar, and C. Poongodi, "Dry machining performance studies on TiAlSiN coated inserts in turning of AISI 420 martensitic stainless steel and multi-criteria decision making using Taguchi-DEAR approach," Silicon, pp. 1-14, 2021.
• [4] A. El-Tamimi, M. Soliman, T. El-Hossainy, and J. Muzher, "Developed models for understanding and predicting the machinability of a hardened martensitic stainless steel," Materials and Manufacturing Processes, vol. 25, no. 8, pp. 758-768, 2010.
• [5] L. Bouzid, M. A. Yallese, K. Chaoui, T. Mabrouki, and L. Boulanouar, "Mathematical modeling for turning on AISI 420 stainless steel using surface response methodology," Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 229, no. 1, pp. 45-61, 2015.
• [6] Ç. V. Yıldırım, Ş. Şirin, T. Kıvak, and M. Sarıkaya, "A comparative study on the tribological behavior of mono&proportional hybrid nanofluids for sustainable turning of AISI 420 hardened steel with cermet tools," Journal of Manufacturing Processes, vol. 73, pp. 695-714, 2022.
• [7] S.-h. Xu, and B. Qiu, "Experimental study on fatigue behavior of corroded steel," Materials Science and Engineering: A, vol. 584, pp. 163-169, 2013.
• [8] Ş. Şirin, and T. Kıvak, "Effects of hybrid nanofluids on machining performance in MQL-milling of Inconel X-750 superalloy," Journal of Manufacturing Processes, vol. 70, pp. 163-176, 2021.
• [9] Ç. V. Yıldırım, "Investigation of hard turning performance of eco-friendly cooling strategies: Cryogenic cooling and nanofluid based MQL," Tribology International, vol. 144, p. 106127, 2020.
• [10] M. K. Gupta, et al., "Experimental characterisation of the performance of hybrid cryo-lubrication assisted turning of Ti–6Al–4V alloy," Tribology International, vol. 153, p. 106582, 2021.
• [11] M. Sarıkaya, Ş. Şirin, Ç. V. Yıldırım, T. Kıvak, and M. K. Gupta, "Performance evaluation of whisker-reinforced ceramic tools under nano-sized solid lubricants assisted MQL turning of Co-based Haynes 25 superalloy," Ceramics International, vol. 47, no. 11, pp. 15542-15560, 2021.
• [12] T. Özel, and T. Altan, "Process simulation using finite element method—prediction of cutting forces, tool stresses and temperatures in high-speed flat end milling," International Journal of Machine Tools and Manufacture, vol. 40, no. 5, pp. 713-738, 2000.
• [13] X. Cui, B. Zhao, F. Jiao, and J. Zheng, "Chip formation and its effects on cutting force, tool temperature, tool stress, and cutting edge wear in high-and ultra-high-speed milling," The International Journal of Advanced Manufacturing Technology, vol. 83, pp. 55-65, 2016.
• [14] M. E. Korkmaz, and M. Günay, "Finite element modelling of cutting forces and power consumption in turning of AISI 420 martensitic stainless steel," Arabian Journal for Science & Engineering (Springer Science & Business Media BV), vol. 43, no. 9, 2018.
• [15] U. Levent, H. Kazan, and Ö. Barış, "Investigation of the Impacts of Cutting Parameters on Power Usage in Cryogenic-Assisted Turning of AISI 52100 Bearing Steel by FEM," İmalat Teknolojileri ve Uygulamaları, vol. 3, no. 3, pp. 55-61, 2022.
• [16] B. Özlü, and L. Uğur, "Optimization of cutting forces on turning of Ti-6Al-4V Alloy by 3D FEM simulation analysis," Journal of Engineering Research and Applied Science, vol. 10, no. 2, pp. 1789-1795, 2021.
• [17] M. Akgün, "Monel K-500 Alaşımının Isı Destekli İşlenmesi Üzerine Sayısal Bir Çalışma," Uluslararası Teknolojik Bilimler Dergisi, vol. 14, no. 1, pp. 23-29, 2022.
• [18] L. Uğur, "A numerical and statistical approach of drilling performance on machining of ti–6al–4v alloy," Surface Review and Letters, vol. 29, no. 12, p. 2250168, 2022.
• [19] H. Wu, and S. Zhang, "3D FEM simulation of milling process for titanium alloy Ti6Al4V," The International Journal of Advanced Manufacturing Technology, vol. 71, no. 5-8, pp. 1319-1326, 2014.
• [20] J.-H. Urrea-Quintero, M. Marino, H. Hernandez, and S. Ochoa, "Multiscale modeling of a free-radical emulsion polymerization process: Numerical approximation by the Finite Element Method," Computers & Chemical Engineering, vol. 140, p. 106974, 2020.
• [21] B. Rao, C. R. Dandekar, and Y. C. Shin, "An experimental and numerical study on the face milling of Ti–6Al–4V alloy: Tool performance and surface integrity," Journal of Materials Processing Technology, vol. 211, no. 2, pp. 294-304, 2011.
• [22] A. Shrot, and M. Bäker, "Determination of Johnson–Cook parameters from machining simulations," Computational Materials Science, vol. 52, no. 1, pp. 298-304, 2012.
• [23] M. Günay, "AISI 316l Çeliğinin işlenmesinde takım radyüsü ve kesme parametrelerinin taguchi yöntemiyle optimizasyonu," Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, vol. 28, no. 3, 2013.
• [24] H. Gürbüz, U. Şeker, and F. Kafkas, "Effects of cutting tool forms on the surface integrity in turning of AISI 316L stainless steel," Journal of the Faculty of Engineering and Architecture of Gazi University, vol. 35, no. 1, pp. 225-240, 2020.
• [25] K. Aydın, Ş. Katmer, A. Gök, and U. Şeker, "Experimental and statistical investigation of the machining performance of wave form end mills on AISI 316L stainless steel," Journal of the Faculty of Engineering and Architecture of Gazi University, vol. 36, no. 4, pp. 2225-2238, 2021.
• [26] I. Ciftci, "Machining of austenitic stainless steels using CVD multi-layer coated cemented carbide tools," Tribology international, vol. 39, no. 6, pp. 565-569, 2006.
• [27] J. Zhao, X. Ai, and Z. L. Li, "Finite element analysis of cutting forces in high speed machining," in Materials Science Forum, Switzerland, 2006, vol. 532: Trans Tech Publications, pp. 753-756.
• [28] H. Gökkaya, G. Sur, and H. Dılıpak, "PVD ve CVD kaplamalı sementit karbür kesici takımların işleme parameterlerine bağlı olarak yüzey pürüzlülüğüne etkisinin deneysel olarak incelenmesi," Teknoloji, vol. 7, no. 3, 2004.
• [29] İ. Çiftçi, "Östenitik paslanmaz çeliklerin işlenmesinde kesici takım kaplamasının ve kesme hızının kesme kuvvetleri ve yüzey pürüzlülüğüne etkisi," Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, vol. 20, no. 2, 2013.
• [30] H. Yeyen, İ. Korkut, Y. Turgut, and İ. Çiftçi, "AISI 303 östenitik paslanmaz çeliklerin işlenmesinde kesme hızı ve ilerlemenin kesme kuvvetleri ve yüzey pürüzlülüğü üzerindeki etkileri," 2009.
• [31] M. F. Abdullah, M. I. H. Chua Abdullah, A. B. Sulong, and J. A. Ghani, "Effects of insert nose radius and processing cutting parameter on the surface roughness of AISI 316 stainless steel," Key Engineering Materials, vol. 447, pp. 51-54, 2010.
• [32] A. Pal, S. Choudhury, and S. Chinchanikar, "Machinability assessment through experimental investigation during hard and soft turning of hardened steel," Procedia Materials Science, vol. 6, pp. 80-91, 2014.
• [33] T. Kıvak, "Optimization of surface roughness and flank wear using the Taguchi method in milling of Hadfield steel with PVD and CVD coated inserts," Measurement, vol. 50, pp. 19-28, 2014.
• [34] R. Işık, B. Özlü, and H. Demir, "St-37 malzemesinin lazer ile kesme işleminde seçilen parametrelerin etkisinin deneysel ve istatiksel olarak incelenmesi," Fırat University Journal of Engineering, vol. 33, no. 1, 2021.