Effects of Tool Edge Geometry and Cutting Conditions on the Performance Indicators in Dry Turning AISI 1045 Steel
This article presents an experimental investigation and statistical analysis of the effects of cutting conditions on the machining performance of AISI 1045 steel using a wiper-shaped insert. Experimental findings are used to compare the machining performance obtained using wiper inserts with those o...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-03-01
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| Series: | Machines |
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| Online Access: | https://www.mdpi.com/2075-1702/11/3/397 |
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| author | Adel T. Abbas Magdy M. El Rayes Abdulhamid A. Al-Abduljabbar Adham E. Ragab Faycal Benyahia Ahmed Elkaseer |
| author_facet | Adel T. Abbas Magdy M. El Rayes Abdulhamid A. Al-Abduljabbar Adham E. Ragab Faycal Benyahia Ahmed Elkaseer |
| author_sort | Adel T. Abbas |
| collection | DOAJ |
| description | This article presents an experimental investigation and statistical analysis of the effects of cutting conditions on the machining performance of AISI 1045 steel using a wiper-shaped insert. Experimental findings are used to compare the machining performance obtained using wiper inserts with those obtained using conventional round-nose inserts as recently reported in the literature. In addition, the effects of process conditions, namely cutting speed, feed rate, and depth of cut, are analyzed in order to obtain optimum conditions for both types of inserts. The goal is to achieve the optimal machining outcomes: minimum surface roughness, resultant cutting force, and cutting temperature, but maximum material removal rate. A full factorial design was followed to conduct the experimental trials, while ANOVA was utilized to estimate the effect of each factor on the process responses. A desirability function optimization tool was used to optimize the studied responses. The results reveal that the optimum material removal rate for wiper-shaped inserts is 67% more than that of conventional inserts, while maintaining a 0.7 µm surface roughness value. The superior results obtained with wiper-shaped inserts allow wiper tools to use higher feed rates, resulting in larger material removal rates while obtaining the same surface quality. |
| first_indexed | 2024-03-11T06:16:01Z |
| format | Article |
| id | doaj.art-28ef44064dcb471594af0cab031f4141 |
| institution | Directory Open Access Journal |
| issn | 2075-1702 |
| language | English |
| last_indexed | 2024-03-11T06:16:01Z |
| publishDate | 2023-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Machines |
| spelling | doaj.art-28ef44064dcb471594af0cab031f41412023-11-17T12:15:56ZengMDPI AGMachines2075-17022023-03-0111339710.3390/machines11030397Effects of Tool Edge Geometry and Cutting Conditions on the Performance Indicators in Dry Turning AISI 1045 SteelAdel T. Abbas0Magdy M. El Rayes1Abdulhamid A. Al-Abduljabbar2Adham E. Ragab3Faycal Benyahia4Ahmed Elkaseer5Department of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi ArabiaDepartment of Industrial Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi ArabiaDepartment of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Fouad 42526, EgyptThis article presents an experimental investigation and statistical analysis of the effects of cutting conditions on the machining performance of AISI 1045 steel using a wiper-shaped insert. Experimental findings are used to compare the machining performance obtained using wiper inserts with those obtained using conventional round-nose inserts as recently reported in the literature. In addition, the effects of process conditions, namely cutting speed, feed rate, and depth of cut, are analyzed in order to obtain optimum conditions for both types of inserts. The goal is to achieve the optimal machining outcomes: minimum surface roughness, resultant cutting force, and cutting temperature, but maximum material removal rate. A full factorial design was followed to conduct the experimental trials, while ANOVA was utilized to estimate the effect of each factor on the process responses. A desirability function optimization tool was used to optimize the studied responses. The results reveal that the optimum material removal rate for wiper-shaped inserts is 67% more than that of conventional inserts, while maintaining a 0.7 µm surface roughness value. The superior results obtained with wiper-shaped inserts allow wiper tools to use higher feed rates, resulting in larger material removal rates while obtaining the same surface quality.https://www.mdpi.com/2075-1702/11/3/397AISI 1045dry turningcutting forcescutting temperaturesurface roughnesswiper-shaped insert |
| spellingShingle | Adel T. Abbas Magdy M. El Rayes Abdulhamid A. Al-Abduljabbar Adham E. Ragab Faycal Benyahia Ahmed Elkaseer Effects of Tool Edge Geometry and Cutting Conditions on the Performance Indicators in Dry Turning AISI 1045 Steel Machines AISI 1045 dry turning cutting forces cutting temperature surface roughness wiper-shaped insert |
| title | Effects of Tool Edge Geometry and Cutting Conditions on the Performance Indicators in Dry Turning AISI 1045 Steel |
| title_full | Effects of Tool Edge Geometry and Cutting Conditions on the Performance Indicators in Dry Turning AISI 1045 Steel |
| title_fullStr | Effects of Tool Edge Geometry and Cutting Conditions on the Performance Indicators in Dry Turning AISI 1045 Steel |
| title_full_unstemmed | Effects of Tool Edge Geometry and Cutting Conditions on the Performance Indicators in Dry Turning AISI 1045 Steel |
| title_short | Effects of Tool Edge Geometry and Cutting Conditions on the Performance Indicators in Dry Turning AISI 1045 Steel |
| title_sort | effects of tool edge geometry and cutting conditions on the performance indicators in dry turning aisi 1045 steel |
| topic | AISI 1045 dry turning cutting forces cutting temperature surface roughness wiper-shaped insert |
| url | https://www.mdpi.com/2075-1702/11/3/397 |
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