Investigation of Carbon Emission During Hard Turning of AISI 4140 Steel with FEM and Regression Methods

Öz

In this study, carbon emission rates during hard turning of AISI 4140 steel alloy, which is widely preferred in the industry due to its high mechanical properties, were investigated. In this context, firstly, Finite Element Method (FEM) simulations were performed with different cutting speed, feed and cutting depth parameters for turning operations. The total carbon emission values were calculated by using the cutting forces and other carbon emission components obtained from the FEM simulations. Then, the carbon emission model was established by Analysis of Variance (ANOVA) and regression analysis. As a result, the lowest carbon emission amount was obtained at 100 m/min cutting speed, 0.3 mm/rev feed rate and 1.5 mm cutting depth. The most effective cutting parameter on carbon emission was found to be cutting speed with a rate of 37.58%. In addition, about 51% of the total carbon emission amount was found to be waste chips and about 41% was found to be carbon emission components from the workpiece.

Anahtar Kelimeler

• Machining
• Hard turning
• AISI 4140
• FEM
• ANOVA
• Cabon emission

AISI 4140 Çelik Alaşımın Sert Tornalanmasındaki Karbon Emisyon Miktarının Sonlu Elemanlar ve Regresyon Yöntemleri ile Analizi

Öz

Bu çalışmada, yüksek mekanik özellikleri sebebiyle endüstride yaygın tercih edilen AISI 4140 çelik alaşımın sert tornalanma sürecinde karbon emisyon miktarları araştırılmıştır. Bu kapsamda, ilk olarak farklı kesme hızı, ilerleme ve kesme derinliği parametreleri ile tornalama sonlu elamanlar metodu (FEM) ile simülasyonları yapılmıştır. FEM simülasyonları sonucunda elde edilen kesme güçleri ve diğer karbon emisyon faktörleri kullanılarak toplam karbon emisyon değerleri hesaplanmıştır. Sonrasında, Varyans analizi (ANOVA) ve regresyon analizleri ile karbon emisyon modeli kurulmuştur. Sonuç olarak, en düşük karbon emisyon miktarı 100 m/dk kesme hızı, 0.3 mm/dev ilerleme ve 1.5 mm kesme derinliği parametrelerinde elde edilmiştir. Karbon emisyon üzerindeki en etkili kesme parametresi, %37,58 oranla kesme hızı olduğu anlaşılmıştır. Ek olarak, toplam karbon emisyon miktarının yaklaşık %51’inin atık talaş ve yaklaşık %41’inin iş malzemesi kaynaklı karbon emisyon bileşenlerinin oluşturduğu görülmüştür.

Anahtar Kelimeler

• Talaşlı imalat
• Sert tornalama
• AISI 4140
• FEM
• ANOVA
• Karbon emisyonu

Kaynakça

1. 1. Khan, W.A., Hayat, Q., Ahmed, F., Ali, M., Zain-ul-Abdein, M. 2023. "Comparative Assessment of Mechanical Properties and Fatigue Life of Conventional and Multistep Rolled Forged Connecting Rods of High Strength AISI/SAE 4140 Steel", Metals, Volume 13, Issue 6, Pages 1035.
2. 2. Sun, X., Liu, G., Liang, X., Tong, S. 2023. "Superior Comprehensive Mechanical Properties of a Low-Carbon Medium Manganese Steel for Replacing AISI 4330 Steel in the Oil and Gas Industry", Materials, Volume 16, Issue 2, Pages 490.
3. 3. Mahmood, N., Hussein, A., Hasan, A.S., Ali, O. Effect of AISI 4140 carbon steel heat treatments on specified mechanical properties. In: AIP Conference Proceedings, 2022. vol 1. AIP Publishing
4. 4. Yadav, P., Singh, J., Srivastava, D.K., Mishra, V. (2021) Environmental pollution and sustainability. In: Environmental sustainability and economy. Elsevier, pp 111-120
5. 5. de la Hoz, J., Martín, H., Guerrero, J.M. 2023. "Technologies and policies for decarbonisation of the industrial and transport sectors", Frontiers in Energy Research, Volume 11, Issue, Pages 1200837.
6. 6. Akšamović, A., Odžak, S. 2023. "Tehnološki napredak i klimatske promjene–tema u obrazovanju inženjera/technological progress and climate change–topic in engineering education", Pregled: časopis za društvena pitanja/Periodical for social issues, Volume, Issue 1, Pages 91-111.
7. 7. Kaygusuz, K. 2021. "Energy efficiency and renewable energy sources for industrial sector", Energy Services Fundamentals and Financing, Volume, Issue, Pages 213-238.
8. 8. Akbar, F., Mativenga, P., Sheikh, M. 2008. "An evaluation of heat partition in the high-speed turning of AISI/SAE 4140 steel with uncoated and TiN-coated tools", Proceedings of the institution of mechanical engineers, Part B: Journal of Engineering Manufacture, Volume 222, Issue 7, Pages 759-771.

9. 9. Tzotzis, A., Efkolidis, N., Tzetzis, D., Kyratsis, P. FEM-based investigation on machining forces and temperatures induced during AISI-4140 hard turning. In: IOP Conference Series: Materials Science and Engineering, 2022. vol 1. IOP Publishing, p 012043
10. 10. Rafighi, M. 2022. "Effects of shallow cryogenic treatment on surface characteristics and machinability factors in hard turning of AISI 4140 steel", Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, Volume 236, Issue 5, Pages 2118-2130.
11. 11. Gürbüz, H., Gönülaçar, Y.E. 2022. "Experimental and statistical investigation of the effects of MQL, dry and wet machining on machinability and sustainability in turning of AISI 4140 steel", Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, Volume 236, Issue 5, Pages 1808-1823.
12. 12. Makhesana, M., Baravaliya, J., Parmar, R., Mawandiya, B., Patel, K. 2021. "Machinability improvement and sustainability assessment during machining of AISI 4140 using vegetable oil-based MQL", Journal of the Brazilian Society of Mechanical Sciences and Engineering, Volume 43, Issue, Pages 1-14.
13. 13. Asiltürk, İ., Kuntoğlu, M., Binali, R., Akkuş, H., Salur, E. 2023. "A Comprehensive Analysis of Surface Roughness, Vibration, and Acoustic Emissions Based on Machine Learning during Hard Turning of AISI 4140 Steel", Metals, Volume 13, Issue 2, Pages 437.
14. 14. Bagga, P.J., Makhesana, M.A., Darji, P.P., Patel, K.M., Pimenov, D.Y., Giasin, K., Khanna, N. 2022. "Tool life prognostics in CNC turning of AISI 4140 steel using neural network based on computer vision", The International Journal of Advanced Manufacturing Technology, Volume 123, Issue 9-10, Pages 3553-3570.
15. 15. Zare Chavoshi, S., Tajdari, M. 2010. "Surface roughness modelling in hard turning operation of AISI 4140 using CBN cutting tool", International journal of material forming, Volume 3, Issue, Pages 233-239.
16. 16. Rafighi, M., Özdemir, M., Das, A., Das, S.R. 2022. "Machinability investigation of cryogenically treated hardened AISI 4140 alloy steel using CBN insert under sustainable finish dry hard turning", Surface Review and Letters, Volume 29, Issue 04, Pages 2250047.
17. 17. Zhou, G., Lu, Q., Xiao, Z., Zhou, C., Tian, C. 2019. "Cutting parameter optimization for machining operations considering carbon emissions", Journal of Cleaner Production, Volume 208, Issue, Pages 937-950.
18. 18. Cao, H., Li, H., Cheng, H., Luo, Y., Yin, R., Chen, Y. 2012. "A carbon efficiency approach for life-cycle carbon emission characteristics of machine tools", Journal of Cleaner Production, Volume 37, Issue, Pages 19-28.
19. 19. Pimenov, D.Y., Mia, M., Gupta, M.K., Machado, Á.R., Pintaude, G., Unune, D.R., Khanna, N., Khan, A.M., Tomaz, Í., Wojciechowski, S. 2022. "Resource saving by optimization and machining environments for sustainable manufacturing: A review and future prospects", Renewable and Sustainable Energy Reviews, Volume 166, Issue, Pages 112660.
20. 20. Khanna, N., Agrawal, C., Dogra, M., Pruncu, C.I. 2020. "Evaluation of tool wear, energy consumption, and surface roughness during turning of inconel 718 using sustainable machining technique", Journal of materials research and technology, Volume 9, Issue 3, Pages 5794-5804.
21. 21. Ghosh, S., Rao, P. 2019. "Comparison between sustainable cryogenic techniques and nano-MQL cooling mode in turning of nickel-based alloy", Journal of cleaner production, Volume 231, Issue, Pages 1036-1049.
22. 22. Öztürk, E. 2022. "FEM and statistical-based assessment of AISI-4140 dry hard turning using micro-textured insert", Journal of Manufacturing Processes, Volume 81, Issue, Pages 290-300.
23. 23. Ma, J., Yong, Y., Lei, S. 3D FEM investigation of the effects of nose radius and edge radius on turning of AISI 4140. In: ASME International Mechanical Engineering Congress and Exposition, 2012. American Society of Mechanical Engineers, pp 1085-1089
24. 24. Lotfi, M., Amini, S., Aghaei, M. 2018. "Tool wear modeling in rotary turning modified by ultrasonic vibration", Simulation Modelling Practice and Theory, Volume 87, Issue, Pages 226-238.
25. 25. Aydin, K. 2023. "Investigating cutting force and cutting power when turning AA6082-T4 alloy at cutting depths smaller than tool nose radius", Kahramanmaraş Sütçü İmam Üniversitesi Mühendislik Bilimleri Dergisi, Volume 26, Issue 4, Pages 972-982.
26. 26. Arrazola, P., Ugarte, D., Dominguez, X. 2008. "A new approach for the friction identification during machining through the use of finite element modeling", International Journal of Machine Tools and Manufacture, Volume 48, Issue 2, Pages 173-183.
27. 27. Özdemir, M., Şahinoğlu, A., Rafighi, M., Yilmaz, V. 2022. "Analysis and optimisation of the cutting parameters based on machinability factors in turning AISI 4140 steel", Canadian Metallurgical Quarterly, Volume 61, Issue 4, Pages 407-417.
28. 28. Sivaramakrishnaiah, M., Kumar, P.N., Janardhana, G.R. 2015. "Prediction of cutting forces in turning of AISI-4140 steel using FEA and experimental validation", i-Manager's Journal on Mechanical Engineering, Volume 6, Issue 1, Pages 24-33.
29. 29. Li, C., Tang, Y., Cui, L., Li, P. 2015. "A quantitative approach to analyze carbon emissions of CNC-based machining systems", Journal of Intelligent Manufacturing, Volume 26, Issue, Pages 911-922.
30. 30. Carbon_Footprint (2022) 2022 Grid Electricity Emissions Factors v0.1 – February 2023. Carbon Footprint. https://www.carbonfootprint.com/docs/2023_02_emissions_factors_sources_for_2022_electricity_v10.pdf. Accessed 20.09.2023
31. 31. Climate_Transparency (2022) Climate Transparency 2022 Report. Climate Transparency. https://www.climate-transparency.org/. Accessed 20.09.2023
32. 32. Circular_Ecology (2019) The Inventory of Carbon and Energy (ICE) database v3.0 - November 2019. Circular Ecology. http://circularecology.com/embodied-carbon-footprint-database.html. Accessed 19.09.2023
33. 33. Motorcu, A., Şahin, Y. 2004. "AISI 4140 Çeliğinin Farklı Kaplamalı Karbür Ve Sermet Kesici Takımlarla İşlenebilirliği", On Birinci Uluslararası Makine Tasarım ve imalat Kongresi, Antalya, Türkiye, Volume, Issue, Pages 13-15.
34. 34. Karayel, B., Nalbant, M. 2014. "Ç4140 Malzemesinin Tornalamasinda İlerleme, Kesme Hizi Ve Kesici Takimin Yüzey Pürüzlülüğü, Takim Ömrü Ve Aşinmaya Etkileri", Makine Teknolojileri Elektronik Dergisi, Volume 11, Issue 3, Pages 11-26.
35. 35. Paengchit, P., Saikaew, C. 2023. "Simulation of the influence of cutting speed and feed rate on tool life in hard turning of AISI 4140 steel", Materials Science-Poland, Volume 41, Issue 2, Pages 311-324.
36. 36. Khrais, S.K., Lin, Y. 2007. "Wear mechanisms and tool performance of TiAlN PVD coated inserts during machining of AISI 4140 steel", Wear, Volume 262, Issue 1-2, Pages 64-69.
37. 37. Jiang, Z., Gao, D., Lu, Y., Kong, L., Shang, Z. 2021. "Quantitative analysis of carbon emissions in precision turning processes and industrial case study", International Journal of Precision Engineering and Manufacturing-Green Technology, Volume 8, Issue, Pages 205-216.
38. 38. Jiang, Z., Gao, D., Lu, Y., Liu, X. 2019. "Optimization of cutting parameters for trade-off among carbon emissions, surface roughness, and processing time", Chinese journal of mechanical engineering, Volume 32, Issue, Pages 1-18.