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Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank

Tool wear, especially flank wear, is a major concern in the manufacturing industry. Increased tool wear is caused by chatter and leads to increased surface roughness, reduced productivity and higher operating costs. It is more pronounced in the machining of difficult to cut materials such as stainle...

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Main Authors: Amin, A. K. M. Nurul, Subir, Siti Aminatuzzuhriyah B. Haji, Arif, Muammer Din
Format: Article
Language:English
English
Published: Trans Tech Publications Ltd., Switzerland 2015
Subjects:
TJ Mechanical engineering and machinery
Online Access:http://irep.iium.edu.my/46246/1/Fist_page_Opt_of_tool_wear_using_RSM-GA_in_s_steel_turning_wt_mag_damp
http://irep.iium.edu.my/46246/2/AMR.1115.117_Opt_of_Tool_Wear_using_RSM-GA_in_Turning_of_S_Steel.pdf
http://irep.iium.edu.my/46246/
http://www.scientific.net/AMR.1115.117
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spelling my.iium.irep.462462016-05-09T05:58:44Z http://irep.iium.edu.my/46246/ Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank Amin, A. K. M. Nurul Subir, Siti Aminatuzzuhriyah B. Haji Arif, Muammer Din TJ Mechanical engineering and machinery Tool wear, especially flank wear, is a major concern in the manufacturing industry. Increased tool wear is caused by chatter and leads to increased surface roughness, reduced productivity and higher operating costs. It is more pronounced in the machining of difficult to cut materials such as stainless steel, tool steel, Inconel and hardened Ti alloys. Additionally, unpredictable tool wear can lead to frequent shutdowns of the machining process making it difficult for full automation. Therefore, to increase productivity and to reduce costs associated with increased and unpredictable tool wear, numerous research studies have been carried out. In this research, two permanent ferrite bar magnets of 1500 Gauss strength were used to dampen the vibration of the tool shank in the turning of stainless steel AISI 304 using titanium nitride (TiN) coated carbide inserts. Mild steel fixtures were used to place the magnets beside and below the tool shank in the carraige of a Harrison M390 engine lathe. The tool overhang was kept constant at 120 mm. A small central composite design (CCD) approach in response surface methodology (RSM) was used to model the tool wear as a response of the three primary cutting parameters: cutting speed, feed, and depth of cut. Design Expert software (version 6) was used to generate the 14 experimental runs needed to develop and verify the empirical mathematical model of tool flank wear. The resultant tool flank wear was measured using both optical and scanning electron microscopes (SEM). Finally, an empirical quadratic mathematical model of tool wear was found. This model was then used as the objective function in the optimization of tool wear using genetic algorithms (GA). The optimization results predicted that the minimum tool wear was 0.0427 mm. This prediction was subsequently validated experimentally. Trans Tech Publications Ltd., Switzerland 2015-07 Article REM application/pdf en http://irep.iium.edu.my/46246/1/Fist_page_Opt_of_tool_wear_using_RSM-GA_in_s_steel_turning_wt_mag_damp application/pdf en http://irep.iium.edu.my/46246/2/AMR.1115.117_Opt_of_Tool_Wear_using_RSM-GA_in_Turning_of_S_Steel.pdf Amin, A. K. M. Nurul and Subir, Siti Aminatuzzuhriyah B. Haji and Arif, Muammer Din (2015) Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank. Advanced Materials Research, 1115. pp. 117-121. ISSN 1662-8985 http://www.scientific.net/AMR.1115.117 10.4028/www.scientific.net/AMR.1115.117
institution Universiti Islam Antarabangsa Malaysia
building IIUM Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider International Islamic University Malaysia
content_source IIUM Repository (IREP)
url_provider http://irep.iium.edu.my/
language English
English
topic TJ Mechanical engineering and machinery
spellingShingle TJ Mechanical engineering and machinery
Amin, A. K. M. Nurul
Subir, Siti Aminatuzzuhriyah B. Haji
Arif, Muammer Din
Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
description Tool wear, especially flank wear, is a major concern in the manufacturing industry. Increased tool wear is caused by chatter and leads to increased surface roughness, reduced productivity and higher operating costs. It is more pronounced in the machining of difficult to cut materials such as stainless steel, tool steel, Inconel and hardened Ti alloys. Additionally, unpredictable tool wear can lead to frequent shutdowns of the machining process making it difficult for full automation. Therefore, to increase productivity and to reduce costs associated with increased and unpredictable tool wear, numerous research studies have been carried out. In this research, two permanent ferrite bar magnets of 1500 Gauss strength were used to dampen the vibration of the tool shank in the turning of stainless steel AISI 304 using titanium nitride (TiN) coated carbide inserts. Mild steel fixtures were used to place the magnets beside and below the tool shank in the carraige of a Harrison M390 engine lathe. The tool overhang was kept constant at 120 mm. A small central composite design (CCD) approach in response surface methodology (RSM) was used to model the tool wear as a response of the three primary cutting parameters: cutting speed, feed, and depth of cut. Design Expert software (version 6) was used to generate the 14 experimental runs needed to develop and verify the empirical mathematical model of tool flank wear. The resultant tool flank wear was measured using both optical and scanning electron microscopes (SEM). Finally, an empirical quadratic mathematical model of tool wear was found. This model was then used as the objective function in the optimization of tool wear using genetic algorithms (GA). The optimization results predicted that the minimum tool wear was 0.0427 mm. This prediction was subsequently validated experimentally.
format Article
author Amin, A. K. M. Nurul
Subir, Siti Aminatuzzuhriyah B. Haji
Arif, Muammer Din
author_facet Amin, A. K. M. Nurul
Subir, Siti Aminatuzzuhriyah B. Haji
Arif, Muammer Din
author_sort Amin, A. K. M. Nurul
title Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_short Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_full Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_fullStr Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_full_unstemmed Optimization of Tool Wear using Coupled RSM-GA Approach in Turning of Stainless Steel AISI 304 with Magnetic Damping of Tool Shank
title_sort optimization of tool wear using coupled rsm-ga approach in turning of stainless steel aisi 304 with magnetic damping of tool shank
publisher Trans Tech Publications Ltd., Switzerland
publishDate 2015
url http://irep.iium.edu.my/46246/1/Fist_page_Opt_of_tool_wear_using_RSM-GA_in_s_steel_turning_wt_mag_damp
http://irep.iium.edu.my/46246/2/AMR.1115.117_Opt_of_Tool_Wear_using_RSM-GA_in_Turning_of_S_Steel.pdf
http://irep.iium.edu.my/46246/
http://www.scientific.net/AMR.1115.117
_version_ 1643612953710166016
score 13.211869

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