Optimization of cutting parameters using Taguchi method during the face milling of AISI 1040 with coated and uncoated inserts
AISI 1040 carbon steel is used in many different sectors such as mold sets, automobile components, transmission shafts, rails and gears. The use of this material in different sectors, its behaviors in the various machining operations have become important. In this study, face milling process was applied to AISI 1040 carbon steel material by using coated and uncoated cutting inserts. Experiments were performed on the basis of Taguchi’s L18 orthogonal array (OA) at different levels of the cutting inserts (Uncoated carbide, CVD / TiN-TiCN-Al2O3 coated carbide, PVD/TiALN coated carbide), the cutting speeds (160, 180, 220 m/min) and the feed rate (0.1, 0.15, 0.3 mm/tooth) and relating to a good surface quality using 0.3 and 0.6 mm cutting depths in whole experiments. The obtained values at the end of the experiments were evaluated through the signal to noise (S/N) ratios and Analysis of Variance (ANOVA). The end of the confirmation experiments, the machining accuracy of 2.90 µm could be significantly improved to 1.42 µm with an enhanced performance of 51.03%.
N. Kavak, N. Üstel, Karaelmas Science and Engineering Journal, 2 (2) (2012) 24-29.
K. Habalı, H. Gökkaya, H. Sert, Politeknik Dergisi, 9 (1) (2006) 35-38.
A. Can, AISI 5140 Çeliğinin Sermet, PVD İle TiAlN - CVD ile TiN Kaplanmış Kesici Uçlarla Tornalanmasında Kesme Değişkenleri, Kaplama Cinsi ve Takım Aşınmasının Yüzey Pürüzlülüğüne Etkisinin Deneysel İncelenmesi, Yüksek Lisans Tezi, G.Ü. Fen Bilimleri Enstitüsü, Makine Eğitim Bölümü, Ankara, (2003).
A. Güllü, Silindirik Taşlamada İstenen Yüzey Pürüzlüğünü Elde Etmek İçin Taşlama Parametrelerinin Bilgisayar Yardımıyla Optimizasyonu, Doktora Tezi, G.Ü. Fen Bilimleri Enstitüsü, Makine Eğitim Bölümü, Ankara, (1995).
F. Kahraman, Materials and Tech. 43 (5) 267–270 (2009).
Özel T. and Karpat, Y International Journal of Machine Tools & Manufacture. (45) 467–479 (2005).
A. Zain Mohd, H. Haron, S. Sharif Expert Systems with App. (37) 1755–1768 (2010).
M. C. Cakir, C. Ensarioğlu, İ. Demirayak, Journal of Materials Proc. Tech. (209) 102–109 (2009).
L. Özler, N. Tosun, A. İnan, Turkish Journal of Eng. and Env. Sciences. (24) 287-296 (2000).
A. Güllü ve A. Özdemir, Gazi Üniv. Fen Bilimleri Dergisi. 16 (1) 127-134 (2003).
I. Asiltürk, M. Çunkaş 2011. Expert Systems with App. (38) 5826–5832 (2011).
M. Brezocnik, M. Kovacic, M. Ficko Journal of Materials Proc. Tech. (157–158) 28–36 (2004).
E. Altınkaya, A. Gülü, Politeknik dergisi, 11(1) 13-17 (2008).
E. S. Topal, Int. Journal of Mech. Sciences, 51 782-789 (2010).
O. Çolak, C. Kurbanoğlu, M. C. Kayacan, Materials and Design, 28 (2007) 657-666.
B. Ozcelik, M. Bayramoğlu, Int. Journal of Machine Tools & Manufacture 46 (2006) 1395-1402.
A. M. Zain, H. Haron, S. Sharif, Expert Systems with App. 37 (2009) 4650-4659.
R. Crpwson, The handbook of manufacturing engineering second edition, parts fabrication: principles and process, Taylor&Francis: Boca Raton (2006).
D.R. Askeland, P.P. Fulay, D.K. Bhattacharya, Essentials of materials science and engineering, second edition, Cengage Learning: Stamford, (2010).
N. S. Kumar, C.K. Dhinakarraj, B. Deepanraj, G. Sankaranarayanan, Multi objective optimization and empirical modelling of centerless grinding parameters, Lecture Notes in Mechanical Engineering, , Sipringer, India, (2012) 285-295.
D. Fratila, C. Caizar, Journal of Cleaner Production, 19 (2011) 640-645
J. R. Davies, Aluminium and aluminium alloys, ASM International, Ohio (1993).
D.T.O. Patrick, D. Newton, R. Bromley, Practical reliability engineering 4thEd. England: John Wiley&Sons (2002).
M. Savaşkan, Y. Taptık, M. Ürgen, Journal of ITU, 3 (2004) 117-128.
M. Nalbant, H. Gokkaya, G. Sur, Materials and Design, 28 (2007) 1379–1385.
K. Krishnaiah, P. Shahabudeen, Applied design of experiments and taguchi methods, PHI Learning Private Limited, New Delhi (2012).
C. Camposeco-Negrete, Journal of Cleaner Production, 53 (2013) 195-203.
J. Antony, D. Preece, Understanding, managing and implementing quality, Frameworks techniques and cases, London, Routledge (2002).
R. K. Roy, A primer on the Taguchi method, competitive manufacturing series, Van Nostrand Reinhold, New York (1990).
İ. Asiltürk, S. Neşeli, Measurement, 45 (4) (2012) 785-794.
C.T. Sun, Quality engineering off-line methods and applications, CRC Press, U.S.A (2013).
W.Y. Fowlkes, C. M. Creveling, Engineering methods for robust product design: using Taguchi Methods in technology and product development, Prentice Hall, New Jersey (1995).
D. K. Baek, T. J. Ko, H. S. Kim, International Journal of Machine Tools & Manufacture, 41 (2001) 451-462.
K. Krishnaiah, P. Shahabedeen, Applied design of experiments and Taguchi Methods, PHI Learning, New Delhi (2012).
İ. Asiltürk, S. Neşeli, Measurement, 45 (2012) 785-794.
G. Halevi, Process and operation planning, Kluwer Academic Publishers, Netherlands (2003).
Y.T. Liu, W.C. Chang, Y. Yamagata, CIRP Journal of Manufacturing Science and Technology, 3 (2010) 40-48.
P. J. Ross, Taguchi techniques for quality engineering, 2nd ed., Mc-Graw-Hill, U.S.A. (1996).
N. Mandal, B. Doloi, B. Mondal, R. Das, Measurement, 44 (2011) 2149-2155
R.K. Roy, Design of experiments using the Taguchi approach, John Wiley&Sons, USA, (2001).