Structural Engineering and Mechanics

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RSM-based MOALO optimization and cutting inserts evaluation in dry turning of AISI 4140 steel

  • Hamadi, Billel (Advanced Technologies in Mechanical Production Research Laboratory (LRTAPM), Badji Mokhtar-Annaba University) ;
  • Yallese, Mohamed Athmane (Mechanics and Structures Research Laboratory (LMS), May 8th 1945 University) ;
  • Boulanouar, Lakhdar (Advanced Technologies in Mechanical Production Research Laboratory (LRTAPM), Badji Mokhtar-Annaba University) ;
  • Nouioua, Mourad (Mechanics Research Center (CRM)) ;
  • Hammoudi, Abderazek (Mechanics Research Center (CRM))
  • Received : 2021.12.13
  • Accepted : 2022.08.10
  • Published : 2022.10.10
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Abstract

An experimental study is carried out to investigate the performance of the cutting tool regarding the insert wear, surface roughness, cutting forces, cutting power and material removal rate of three coated carbides GC2015 (TiCN-Al2O3-TiN), GC4215 (Al2O3-Ti(C,N)) and GC1015 (TiN) during the dry turning of AISI4140 steel. For this purpose, a Taguchi design (L9) was adopted for the planning of the experiments, the effects of cutting parameters on the surface roughness (Ra), tangential cutting force (Fz), the cutting power (Pc) and the material removal rate (MRR) were studied using analysis of variance (ANOVA), the response surface methodology (RSM) was used for mathematical modeling, with which linear mathematical models were developed for forecasting of Ra, Fz, Pc and MRR as a function of cutting parameters (Vc, f, and ap). Then, Multi-Objective Ant Lion Optimizer (MOALO) has been implemented for multi-objective optimization which allows manufacturers to enhance the production performances of the machined parts. Furthermore, in order to characterize and quantify the flank wear of the tested tools, some machining experiments were performed for 5 minutes of turning under a depth of 0.5 mm, a feed rate of 0.08 mm/rev, and a cutting speed of 350 m/min. The wear results led to a ratio (VB-GC4215/VB-GC2015) of 2.03 and (VB-GC1015/VB-GC2015) of 4.43, thus demonstrating the efficiency of the cutting insert GC2015. Moreover, SEM analysis shows the main wear mechanisms represented by abrasion, adhesion and chipping.

Keywords

Acknowledgement

This work was achieved in the Mechanics and Structures Research Laboratory (LMS), May 8th 1945 University, Guelma, Algeria in collaboration with the Advanced Technologies in Mechanical Production Research Laboratory (LRTAPM), Badji Mokhtar-Annaba University, Algeria. The authors would like to thank the Research Centre in Industrial Technologies and the Thin Films Development and Applications Unit for their assistance.

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