Structural Engineering and Mechanics

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Machinability investigation of gray cast iron in turning with ceramics and CBN tools: Modeling and optimization using desirability function approach

  • Boutheyna Gasmi (Department of Mechanical Engineering, Mechanics and Structure Laboratory (LMS), University 8 Mai 1945) ;
  • Boutheyna Gasmi (Department of Mechanical Engineering, Mechanics and Structure Laboratory (LMS), University 8 Mai 1945) ;
  • Septi Boucherit (Department of Mechanical Engineering, Mechanics and Structure Laboratory (LMS), University 8 Mai 1945) ;
  • Salim Chihaoui (Department of Mechanical Engineering, Mechanics and Structure Laboratory (LMS), University 8 Mai 1945) ;
  • Tarek Mabrouki (Applied Mechanics and Engineering Laboratory, University of Tunis El Manar, ENIT)
  • Received : 2022.12.20
  • Accepted : 2023.03.06
  • Published : 2023.04.10
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Abstract

The purpose of this research is to assess the performance of CBN and ceramic tools during the dry turning of gray cast iron EN GJL-350. During the turning operation, the variable machining parameters are cutting speed, feed rate, depth of cut and type of the cutting material. This contribution consists of two sections, the first one deals with the performance evaluation of four materials in terms of evolution of flank wear, surface roughness (2D and 3D) and cutting forces. The focus of the second section is on statistical analysis, followed by modeling and optimization. The experiments are conducted according to the Taguchi design L32 and based on ANOVA approach to quantify the impact of input factors on the output parameters, namely, the surface roughness (Ra), the cutting force (Fz), the cutting power (Pc), specific cutting energy (Ecs). The RSM method was used to create prediction models of several technical factors (Ra, Fz, Pc, Ecs and MRR). Subsequently, the desirability function approach was used to achieve a multi-objective optimization that encompasses the output parameters simultaneously. The aim is to obtain optimal cutting regimes, following several cases of optimization often encountered in industry. The results found show that the CBN tool is the most efficient cutting material compared to the three ceramics. The optimal combination for the first case where the importance is the same for the different outputs is Vc=660 m/min, f=0.116 mm/rev, ap=0.232 mm and the material CBN. The optimization results have been verified by carrying out confirmation tests.

Keywords

Acknowledgement

The present research was undertaken by the "Metal Cutting Research Group" of the (LMS) Laboratory of the 8 May 1945-Guelma University, Algeria.

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