Modeling and multi-response optimization of machining performance while turning hardened steel with self-propelled rotary tool

doi:10.1007/s40436-014-0092-z

Advances in Manufacturing ›› 2015, Vol. 3 ›› Issue (1): 84-95.doi: 10.1007/s40436-014-0092-z

• • 上一篇

Modeling and multi-response optimization of machining performance while turning hardened steel with self-propelled rotary tool

Thella Babu Rao¹, A. Gopala Krishna², Ramesh Kumar Katta³, Konjeti Rama Krishna¹

1. Department of Mechanical Engineering, GITAM University, Hyderabad 502329, Andhra Pradesh, India;
2. Department of Mechanical Engineering, University College of Engineering, JNTUK, Kakinada 533003, Andhra Pradesh, India;
3. Productionisation & Technology Transfer, Defence R&D Laboratory, Kanchanbagh, Hyderabad 500058, Andhra Pradesh, India

收稿日期:2014-03-09 修回日期:2014-10-31 出版日期:2015-03-25 发布日期:2014-11-30
通讯作者: T. B. Rao, e-mail: baburao_thella@yahoo.co.in E-mail:baburao_thella@yahoo.co.in

Modeling and multi-response optimization of machining performance while turning hardened steel with self-propelled rotary tool

Thella Babu Rao¹, A. Gopala Krishna², Ramesh Kumar Katta³, Konjeti Rama Krishna¹

1. Department of Mechanical Engineering, GITAM University, Hyderabad 502329, Andhra Pradesh, India;
2. Department of Mechanical Engineering, University College of Engineering, JNTUK, Kakinada 533003, Andhra Pradesh, India;
3. Productionisation & Technology Transfer, Defence R&D Laboratory, Kanchanbagh, Hyderabad 500058, Andhra Pradesh, India

Received:2014-03-09 Revised:2014-10-31 Online:2015-03-25 Published:2014-11-30
Contact: T. B. Rao, e-mail: baburao_thella@yahoo.co.in E-mail:baburao_thella@yahoo.co.in

摘要/Abstract

摘要： There are many advanced tooling approaches in metal cutting to enhance the cutting tool performance for machining hard-to-cut materials. The self propelled rotary tool (SPRT) is one of the novel approaches to improve the cutting tool performance by providing cutting edge in the form of a disk, which rotates about its principal axis and provides a rest period for the cutting edge to cool and allow engaging a fresh cutting edge with the work piece. This paper aimed to present the cutting performance of SPRT while turning hardened EN24 steel and optimize the machining conditions. Surface roughness (R_a) and metal removal rate (^rMMR) are considered as machining performance parameters to evaluate, while the horizontal inclination angle of the SPRT, depth of cut, feed rate and spindle speed are considered as process variables. Initially, design of experiments (DOEs) is employed to minimize the number of experiments. For each set of chosen process variables, the machining experiments are conducted on computer numerical control (CNC) lathe to measure the machining responses. Then, the response surface methodology (RSM) is used to establish quantitative relationships for the output responses in terms of the input variables. Analysis of variance (ANOVA) is used to check the adequacy of the model. The influence of input variables on the output responses is also determined. Consequently, these models are formulated as a multi-response optimization problem to minimize the R_a and maximize the rMMR simultaneously. Non-dominated sorting genetic algorithm-II (NSGA-II) is used to derive the set of Pareto-optimal solutions. The optimal results obtained through the proposed methodology are also compared with the results of validation experimental runs and good correlation is found between them.

关键词: Self-propelled rotary turning, Empirical modeling, Response surface methodology (RSM), Multiobjective formulation, Optimization, Non-dominated sorting genetic algorithm-II (NSGA-II)

Abstract: There are many advanced tooling approaches in metal cutting to enhance the cutting tool performance for machining hard-to-cut materials. The self propelled rotary tool (SPRT) is one of the novel approaches to improve the cutting tool performance by providing cutting edge in the form of a disk, which rotates about its principal axis and provides a rest period for the cutting edge to cool and allow engaging a fresh cutting edge with the work piece. This paper aimed to present the cutting performance of SPRT while turning hardened EN24 steel and optimize the machining conditions. Surface roughness (R_a) and metal removal rate (^rMMR) are considered as machining performance parameters to evaluate, while the horizontal inclination angle of the SPRT, depth of cut, feed rate and spindle speed are considered as process variables. Initially, design of experiments (DOEs) is employed to minimize the number of experiments. For each set of chosen process variables, the machining experiments are conducted on computer numerical control (CNC) lathe to measure the machining responses. Then, the response surface methodology (RSM) is used to establish quantitative relationships for the output responses in terms of the input variables. Analysis of variance (ANOVA) is used to check the adequacy of the model. The influence of input variables on the output responses is also determined. Consequently, these models are formulated as a multi-response optimization problem to minimize the R_a and maximize the rMMR simultaneously. Non-dominated sorting genetic algorithm-II (NSGA-II) is used to derive the set of Pareto-optimal solutions. The optimal results obtained through the proposed methodology are also compared with the results of validation experimental runs and good correlation is found between them.

Key words: Self-propelled rotary turning, Empirical modeling, Response surface methodology (RSM), Multiobjective formulation, Optimization, Non-dominated sorting genetic algorithm-II (NSGA-II)

Thella Babu Rao, A. Gopala Krishna, Ramesh Kumar Katta, Konjeti Rama Krishna. Modeling and multi-response optimization of machining performance while turning hardened steel with self-propelled rotary tool[J]. Advances in Manufacturing, 2015, 3(1): 84-95.

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Modeling and multi-response optimization of machining performance while turning hardened steel with self-propelled rotary tool

Modeling and multi-response optimization of machining performance while turning hardened steel with self-propelled rotary tool

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