Optimization Of Turning Parameters For Surface Roughness Of AISI 1040 steel Using ANN

Un er The !ui ance Of" Mr. Amiya Kumar Sahoo

Presente #$" %unen era Pal Singh Enr. No.:- 122403

M.Tech In Manufacturing Tech. Department Of Mechanical Engineering Jaypee University Of Engineering & Technology, Guna

&ontents

Pro'lem statement Importance of surface finish %aterial selection (ffects of chemical elements Process selection Parameters an their influence )iterature sur*e$ References

Pro'lem statement

In the manufacturing in ustries *arious processes are a opte to remo*e the material from +or,piece- Out of these . turning is the most common metho for metal cutting 'ecause of its a'ilit$ to remo*e material faster +ith a reasona'le goo surface /ualit$In actual practice there are man$ factors +hich affect surface roughness so it is ifficult to control all the factors !enerall$ . esire parameters are selecte 'ase on e0perience or use '$ the han 'oo,- #ut a 'etter result ma$ 'e achie*e '$ optimizing the cutting parameters-

Importance of surface finish

As the surface finishing affecte the fatigue life of a material. the machining process must 'e consi ere this parameter in or er to minimize the cost an time in pro ucing a pro uctthe final surface roughness also affects se*eral functional attri'utes li,e friction. +earing. light reflection. heat transmission. coating an a'ilit$ of istri'uting an hol ing a lu'ricantIn or er to impro*e the fatigue strength. corrosion resistance an aesthetic appeal of the pro uct. a reasona'l$ goo surface finish is esire %anufacturing in ustries speciall$ concerne imensional accurac$ an surface finishto

%aterial selection

The material selection is one on the 'asis of composition of ifferent allo$ing elements an their effect on properties of allo$ steelThe sample material +as AISI 1040 steel in the form of roun 'arsThe chemical composition of AISI 1040 in mass1 is as follo+s" 0-234&. 0-546Si. 0-677%n. 0-0133P. 0-0455S.0-0458&r. 0-0536%o. 0-103NiThis steel is especiall$ recommen e for the manufacture of transmission shaft. gear an rail+a$- It is also suita'le for a +i e *ariet$ of automoti*e9 t$pe applications-

Effects of
!.

hemical Elements

ar"on is the principal har ening element in steel. +ith each a itional increment of car'on increasing the har ness an tensile strength of the steelManganese enhances corrosion resistance an increases +ear resistance%hosphorus enhances strength. machina'ilit$ an corrosion resistanceSulphur is a e to impro*e machina'ilit$:hereas sulphi es in steel act as effecti*e chip9'rea,ers to impro*e machina'ilit$'ic(el pro*i es impro*e impro*e corrosion resistancetoughness.

#.

$.

4-

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).

hromium is use pro*i e impro*e car'urization-

in allo$ steels to increase har ena'ilit$. a'rasion9resistance. an to promote

*.

Moly"+enum e0hi'its a greater effect on har ena'ilit$ per unit a e than an$ other commonl$ specifie allo$ing element e0cept manganese-ana+ium impro*es the strength an toughness of thermall$ treate steels. primaril$ 'ecause of its a'ilit$ to inhi'it grain gro+th o*er a fairl$ 'roa /uenching range/ilicon is one of the principal steelma,ing- Silicon is less effecti*e increasing as9rolle strength an har steels. silicon is generall$ etrimental to eo0i izers use in than manganese in ness- In lo+9car'on surface /ualit$-

,.

..

Process selection
For selecting a manufacturing process. follo+ing points shoul 'e gi*en ue consi eration"9
152-

%anufacturing costPro uction *olume ; pro uction rate&haracteristics an materialproperties of +or,piece

44-

Re/uire shape ; sizeSurface finish re/uirement-

Shaft pro uction techni/ues

Shaft can 'e pro uce '$ man$ processesSome of them are "9

Turning Forging &asting (0trusion

:h$ turning <

There are man$ reasons 'ehin selecting Turning as the shaft manufacturing process some of those are "9

Shaft can onl$ 'e pro uce turning on lathe-

economicall$. '$

oing

In comparison to other manufacturing processes energ$ consumption in turning is lessThere is also re eposition +hich causes +el ing of micro9chips in grin ing +hich effects surface roughness#ul, material remo*al is possi'le in turning +hich is a main ra+'ac, in grin ing-

Parameter

PARA%(T(RS AN= T>(IR INF)U(N&( ON SURFA&( FINIS>

Influence and interrelationship

Cutting speed, depth of cut, feed, and cutting fluids. Tool angles

Cutting Forces, power, temperature rise, tool life, type of chips, surface finish.

Influence on chip flow direction; resistance to tool chipping.

Continuous chip

ood surface finish; steady cutting forces; undesira!le in automated machinery.

Built-up-edge chip

Poor surface finish, thin sta!le edge can produce rough tool surface.

Discontinuous chip

Desira!le for ease of chip disposal; fluctuating cutting forces; can affect surface finish and cause "i!ration and chatters.

Temperature rise

Influences surface finish, dimensional accuracy, temperature rise, forces and power.

Tool wear

Influences surface finish, dimensional accuracy, temperature rise, forces and power.

)iterature re*ie+

Author "9 Sahoo. P- ?5011@ %aterial use "9AISI 1040 mil steel %achine use "9AO##(RB) &N& lathe Tool use "9 Titanium nitri e coate car'i e tools &utting con ition"9=r$ Optimization techni/ue use "9 RS% It is seen that the *alue of surface roughness ecreases +ith increase in =-O-& an spin le spee 'ut increase +ith increase in fee rate In confirmation test it is seen that the e0perimental mean *alue of surface roughness comes out to 'e -834Cm Cm +hich is *er$ close to the optimum *alue -874Cm

Author "9 Sule$man Neseli et- al- ?5011@ %aterial use "9 AISI 1040 steel %achine use "9 >arrison %200 lathe Tool use "9 Al5O2DTi& tools &utting con itions "9=r$ Optimization techni/ue use "9 RS% In this stu $. it is foun that the tool nose ra ius increase causes to increases of surface roughnessThe e*elope mo el can 'e effecti*el$ use to pre ict the surface roughness on the machining of AISI 1040 steel +ith in 741 confi ence inter*als ranges of parameters stu ie -

Author "9 S-S-&hau hari et- al- ?5015@ %aterial use "9 AISI 1040 steel %achine use "9 &N& lathe ?>955@ Tool use "9 TiN coate tungsten car'i e inserts &utting con ition"9 %E) ?*egeta'le oil@ Optimization techni/ue use "9 Taguchi metho The e0perimental result anal$sis sho+e that the com'ination of higher le*els of cutting spee . epth of cut an lo+er le*el of fee is essential to achie*e simultaneous ma0imization of material remo*al rate an minimization of surface roughnessIn confirmation test it is seen that the e0perimental *alue of surface roughness comes out to 'e 0-484Cm +hich is *er$ close to the optimum *alue 0-424Cm-

Author "9 Poornima ; Su,umar ?5015@ %aterial use "9Stainless steel ?SS40@ %achine use "9 Uni*ersal lathe machine Tool use "9&#N inserts &utting con ition"9=r$ Optimization techni/ue use "9 RS% In this stu $ the fee . epth of cut ; spee significantl$ effect the response ?surface roughness@ Using RS% In confirmation test it is seen that the e0perimental mean *alue of surface roughness comes out to 'e -64 Cm +hich is *er$ close to the optimum *alue -64Cm

Author "9 >ari singh an Pra eep ,umar ?5006@ %aterial use "9(n 54 steel %achine use "9 &N& lathe ?>955@ Tool use "9Ti& &oate car'i e inserts &utting con ition"9=r$ Optimization techni/ue use "9Taguchi metho In this stu $ it is foun ominant parameter that cutting spee is the

In confirmation test it is seen that the e0perimental mean *alue of surface roughness comes out to 'e -81 Cm +hich is *er$ close to the optimum *alue -67Cm

Author "9 Fran,o Puh et al%aterial use "9 >ar ene steel AISI 4145 %achine use "9 &N& lathe machine FSafop9)eonar 30D1800F Tool use "9 P&#N &utting con itions"9 %etal+or,ing flui of 31 concentration Optimization techni/ue use "9Taguchi metho The e0perimental results in icate that in this stu $ fee rate e0erte the greatest effect on surface roughness. follo+e '$ epth of cutThe a*erage result of the confirmation test at the optimum con ition is e0pecte to 'e +ithin 0-546 an 0-574 Gm +ith confi ence of 84 1-

References

%- Hala har. H- Ien,ata Su''aiah. &h- Srini*asa Rao an H- Nara$ana Rao- ?5010@JOptimization of process parameters in turning of aisi505 austenitic stainless steel KARPN Aournal of (ngineering an Applie Sciences - *ol 113. pp 2049208Ali Riza %otorcu. ?5010@- JThe optimization of machining parameters using the Taguchi %etho for surface roughness of AISI 8330 har ene allo$ steelK- Aournal of %echanical (ngineering - Iol 43 .pp 2719401%ahen ra Horat an NeeraL Agar+al . ?5015@- JOptimization of ifferent machining parameters of en54 allo$ steel in cnc turning '$ use of taguchi metho K- International Aournal of (ngineering Research an Applications ?IA(RA@ - Iol 5. pp- 1309134Poornima an Su,umar ?5015@-JOptimization of machining parameters in cnc turning of martensitic stainless steel using rsm0 - International Aournal of %o ern (ngineering Research ?IA%(R@ -*ol-56. pp-364M380>ari singh an Pra eep ,umar ?5006@- J%athematical mo els of tool life an surface roughness for turning operation through response surface metho olog$K- Aournal of Scientific ; In ustrial Research- *ol- 33 . pp- 5509553Fran,o Puh. Toni Segota an Noran Aur,o*ic?5015@- JOptimization of har turning process parameters +ith pc'n tool 'ase on the taguchi metho K- Aournal of TehniO,i *Lesni, - *ol-17. pp- 4149417-