Abstract
The demand for the machining and cutting of plastic parts is in continuous increase. The present study is intended to investigate the optimization of high density polyethylene (HDPE-100) orthogonal turning operation using the Grey Relational Analysis (GRA). Accordingly, experimental tests based on Taguchi method are performed to establish a correlation between cutting parameters on one hand and machining force, specific cutting force and roughness of machined surface on the other hand. An optimal parameters combination for the turning process is obtained. In addition to regression models deduction, the analysis of variance (ANOVA) is applied to identify the most significant factors. It is found that the order of the importance of controllable factors to the tangential cutting force (Ft) is feed rate (f), depth of cut (ap) and cutting speed (Vc). However, when considering the importance with respect to specific cutting force (Ks), the order becomes (Vc), (ap) and (f). Finally, the order of cutting parameters according to mean roughness criteria, represented by (Ra), (Rz) and (Rt), shifts to (f), (Vc) and (ap). The optimized cutting regime ensuring minimization of roughness and cutting forces is well described by Vc = 188 m/min, f = 0.14 mm/rev and ap = 3 mm. This study unveiled new approaches based on combined GRA and ANOVA for machining other polymers such as tough reinforced polymers and composites used as human prosthesis.
References
Alauddin, M., Choudhury, I. A., El Baradie, M. A. and HashmiM. S. J., “Plastics and their Machining: A Review”, J. Mater. Process. Technol., 54, 40–46 (1995) 10.1016/0924-0136(95)01917-0Search in Google Scholar
Benardos, P. G., Vosniakos, G. C., “Predicting Surface Roughness In Machining: A Review”, Int. J. Mach. Tools Manuf., 43, 833–844 (2003) 10.1016/S0890-6955(03)00059-2Search in Google Scholar
Cabrera, F. M., Hanafi, I., Khamlichi, A., Jabbouri, A. and Bezzazi, M., “Sur l'Usinabilité des Composites a Matrices Polymères Renforcée par des Fibres”, Mech. Ind., 11, 93–103 (2010)Search in Google Scholar
Carr, J. W., Feger, C., “Ultra Precision Machining of Polymers”, Precis. Eng., 15, 221–237 (1993) 10.1016/0141-6359(93)90105-JSearch in Google Scholar
Cheng, J. J., Polak, M. A. and Penlidis, A., “Influence of Micro-Molecular Structure on Environmental Stress Cracking Resistance of High Density Polyethylene”, Tunnelling Underground Space Technol., 26, 582–593 (2011) 10.1016/j.tust.2011.02.003Search in Google Scholar
Colin, X., Verdu, J. and Rabaud, B., “Chapter 4 Degradation of Polyethylene Pipes by Water Disinfectants”, in Water Disinfection, BuchananK.M. (Ed.), Nova Science Publishers, New York, p. 109–142 (2011)Search in Google Scholar
Danhui, D., Sun, L., Guo, Y. and Cheng, W., “Study on the Mechanical Properties of Stay Cable HDPE Sheathing Fatigue in Dynamic Bridge Environments”, Polymer, 7, 1564–1576 (2015)10.3390/polym7081470Search in Google Scholar
Kartal, F., Çetin, M. H., Gökkaya, H., and Yerlikaya, Z., “Optimization of Abrasive Water Jet Turning Parameters for Machining of Low Density Polyethylene Material Based on Experimental Design Method”, Int. Polym. Proc., 29, 535–544 (2014) 10.3139/217.2925Search in Google Scholar
Gombette, P., Ernoult, I.: Physique des Polymères: II. Propriétés Mécaniques, Herman Editors, Paris (2005)Search in Google Scholar
Hanafi, I., Cabrera, F. M., Khamlichi, A., Garrido, I. and Manzanares, J. T., “Artificial Neural Networks Back Propagation Algorithm for Cutting Force Components Predictions”, Mech. Ind., 14, 431–439 (2013)10.1051/meca/2013084Search in Google Scholar
Hubert, L., David, L., Seguela, R., Vigier, G., Degoulet, C., and Germain, Y., “Physical and Mechanical Properties of Polyethylene for Pipes in Relation to Molecular Architecture. I. Microstructure and Crystallization Kinetics”, Polymer, 42, 8425–8434 (2001) 10.1016/S0032-3861(01)00351-2Search in Google Scholar
Humbert, S., Lame, O. and Vigier, G., “Polyethylene Yielding Behavior: What Is behind the Correlation between Yield Stress and Crystallinity?”, Polymer, 50, 3755–3761 (2009) 10.1016/j.polymer.2009.05.017Search in Google Scholar
Kaddeche, M., Chaoui, K. and Yallese, M. A., “Cutting Parameters Effects on the Machining of Two High Density Polyethylene Pipes Resins”, Mech. Ind., 13, 307–316 (2012)10.1051/meca/2012029Search in Google Scholar
Lin, C. L., “Use of the Taguchi Method and Grey Relational Analysis Turning Operations with Multiple Performance Characteristics”, Mater. Manuf. Processes, 19, 209–220 (2004) 10.1081/AMP-120029852Search in Google Scholar
Lin, J. L., Lin, C. L., “The Use of the Orthogonal Array with Grey Relational Analysis to Optimize the Electrical Discharge Machining Process with Multiple Performance Characteristics”, Int. J. Mach. Tools Manuf., 42, 237–244 (2002) 10.1016/S0890-6955(01)00107-9Search in Google Scholar
Mukherjee, I., Ray, P. K., “A Review of Optimization Techniques in Metal Cutting Processes”, Comput. Ind. Eng., 50, 15–34 (2006) 10.1016/j.cie.2005.10.001Search in Google Scholar
Nayak, S., Routara, B. C, “Optimization of Multiple Performance Characteristics in Electro Discharge Machining Using Grey Relational Analysis”, Int. J. Sci. Tech. Res., 3, 116–121 (2014)Search in Google Scholar
Nitta, K. H., Maeda, H., “Creep Behavior of High Density Polyethylene under a Constant True Stress”, Polym. Test., 29, 60–65 (2010) 10.1016/j.polymertesting.2009.09.005Search in Google Scholar
Noorul Haq, A., MarimuthuP. and JeyapaulR., “Multi Response Optimization of Machining Parameters of Drilling Al/SiC Metal Matrix Composite Using Grey Relational Analysis in the Taguchi Method”, Int. J. Adv. Manuf. Technol., 37, 250–255 (2008) 10.1007/s00170-007-0981-4Search in Google Scholar
Pusz, A., Michalik, K., “Creep Damage Mechanisms in Gas Pipes Made of High Density Polyethylene”, AMSE, 36, 89–95 (2009)Search in Google Scholar
Rehab-Bekkouche, S., Ghabeche, W., Kaddeche, M., Kiass, N. and Chaoui, K., “Mechanical Behaviour of Machined Polyethylene Filaments Subjected to Aggressive Chemical Environments”, Mechanika, 3, 40–46 (2009)Search in Google Scholar
Ross, P. J: Taguchi Techniques for Quality Engineering, McGraw-Hill, New York (1996)Search in Google Scholar
Sahoo, P., Pal, S. K., “Tribological Performance Optimization of Electroless Ni-P Coatings Using the Taguchi Method and Grey Relational Analysis”, Tribol. Lett., 28, 191–201 (2007) 10.1007/s11249-007-9264-3Search in Google Scholar
Siddhi Jailani, H., Rajadurai, A., Mohan, B., Senthil Kumar, A. and Sornakumar, T., “Multi-Response Optimization of Sintering Parameters of Al-Si Alloy/Fly Ash Composite Using Taguchi Method and Grey Relational Analysis”, Int. J. Adv. Manuf. Technol., 45, 362–369 (2009) 10.1007/s00170-009-1973-3Search in Google Scholar
Smith, E. F., “Single Point Turning of Amorphous Thermoplastic Polymers”, Master's Thesis, North Carolina St. U., Raleigh, NC, USA (1989)Search in Google Scholar
Tosun, N., “Determination of Optimum Parameters for Multi Performance Characteristics in Drilling by Using Grey Relational Analysis”, Int. J. Adv. Manuf. Technol., 28, 450–455 (2006) 10.1007/s00170-004-2386-ySearch in Google Scholar
Tsao, C. C., “Grey-Taguchi Method to Optimize the Milling Parameters of Aluminum Alloy”, Int. J. Adv. Manuf. Technol., 40, 41–48 (2009) 10.1007/s00170-007-1314-3Search in Google Scholar
Xiao, K. O, Zhang, L. C., “The Role of Viscous Deformation in the Machining of Polymers”, Int. J. Mech. Sci., 44, 2317–2336 (2002a) 10.1016/S0020-7403(02)00178-9Search in Google Scholar
Xiao, K. O., Zhang, L. C., “Effects of Polymer Properties on the Surface Finish and Chip Formation, in Orthogonal Cutting” in Applied Mechanics Progress and Applications”, Zhang, L. C., Tong, L., Gal, J. (Eds.), Proceeding 3rd Australian Congress on Applied Mechanics, World Scientific Publishers, Singapore, p. 279 (2002b)10.1142/9789812777973_0045Search in Google Scholar
Yusup, N., ZainA.M. and HashimS.M., “Evolutionary Techniques in Optimizing Machining Parameters: Review and Recent Applications (2007–2011)”, Expert Syst. Apl., 39, 9909–9927 (2012) 10.1016/j.eswa.2012.02.109Search in Google Scholar
© 2016, Carl Hanser Verlag, Munich
