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Taguchi optimization of surface roughness and flank wear during the turning of DIN 1.2344 tool steel

Taguchi-Optimierung der Oberflächenrauheit und des Flankenverschleißes eines DIN 1.2344 Werkzeugstahles beim Drehen
  • Fuat Kara
From the journal Materials Testing

Abstract

In this study, a turning operation was applied to DIN 1.2344 hot work tool steel under dry machining conditions. The optimum machining conditions were determined by investigating the surface roughness (Ra) and the flank wear (Vb) depending on the machining parameters. Experiments were performed according to the Taguchi L9 orthogonal array and signal/noise (S/N) ratios were used in the evaluation of the test results. Optimum Ra and Vb values were determined by Taguchi optimization. The effects of the machining parameters on Ra and Vb were found with the help of analysis of variance (ANOVA). According to the ANOVA results, the most important parameter affecting Ra and Vb was feed rate. Two different multiple regression analyses (linear and quadratic) were conducted for the experimental results. A higher correlation coefficient (R2) was obtained with the quadratic regression model, which showed a value of 0.99 for both Ra and Vb. Finally, confirmation tests were performed and showed that the optimization has been successfully implemented. By the Taguchi analysis the optimum results for both surface roughness and flank wear were found to be a cutting speed of 120 m × min−1, a feed rate of 0.15 mm × rev−1 and a depth of cut of 0.5 mm. The results of the calculations and the confirmation tests for Ra were 0.84 μm and 0.80 μm, and for Vb, 0.0892 mm and 0.0824 mm, respectively.

Kurzfassung

In der diesem Beitrag zugrundeliegenden Studie wurde der Warmarbeitsstahl DIN 1.2344 einer Drehbearbeitung unter trockenen Bedingungen unterzogen. Die optimalen Bearbeitungsbedingungen wurden untersucht, indem die Oberflächenrauheit (Ra) und der Flankenabtrag (Vb) abhängig von den Bearbeitungsparametern untersucht wurden. Es wurden Experimente durchgeführt, und zwar unter Verwendung des entsprechenden Taguchi L9 orthogonalen Arrays und der Signal-Rausch-Abstandsverhältnisse S/N zur Evaluation der Ergebnisse. Die Auswirkungen der Bearbeitungsparameter auf die Werte von Ra und Vb wurden mittels Varianzanalyse ermittelt (ANOVA). Entsprechend der ANOVA-Ergebnisse ist der bedeutendste Parameter, der die Werte von Ra und Vb beeinflusst, die Vorschubrate. Bezüglich der experimentellen Ergebnisse wurden multiple Regressionsanalysen (linear und quadratisch) durchgeführt. Mit dem quadratischen Regressionsmodell stellte sich ein höherer Korrelationskoeffizient R2 ein, der einen Wert von 0,99 für die beiden Parameter Ra und Vb hat. Schließlich wurden Validierungsversuche durchgeführt, die zeigen, dass die Optimierung erfolgreich implementiert wurde. Mit der Taguchi-Analyse wurden optimale Ergebnisse hinsichtlich der Oberflächenrauheit und des Flankenverschleißes für eine Schnittgeschwindigkeit von 120 m × min−1, eine Vorschubrate von 0.15 mm × rev−1 und eine Schnitttiefe von 0.5 mm ermittelt. Die Ergebnisse der Berechnungen und der Validierungsversuche betrugen für Ra 0.84 μm und 0.80 μm bzw. für Vb 0.0892 mm und 0.0824 mm.


*Correspondence Address, Assist. Prof. Dr. Fuat Kara, Düzce University, Faculty of Technology, Department of Manufacturing Engineering, 81620, Düzce, Turkey, E-mail:

Dr. Fuat Kara is Assistant Professor in the Department of Manufacturing Engineering at Düzce University, Düzce, Turkey. He completed his BSc degree at the University of Dumlupınar, Kütahya, Turkey in 2005 and his MSc degree at the University of Afyon Kocatepe, Afyonkarahisar, Turkey in 2010. He received his PhD degree in Mechanical Education from the University of Karabük, Karabük, Turkey in 2014. His research interests are machining, cryogenic treatment, Taguchi method, ANOVA and regression analysis.


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Published Online: 2017-10-02
Published in Print: 2017-10-04

© 2017, Carl Hanser Verlag, München

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