Experimental Investigation and Statistical Evaluation of Optimized Cutting Process Parameters and Cutting Conditions to Minimize Cutting Forces and Shape Deviations in Al6026-T9

Muhammad Abas; Bashir Salah; Qazi Salman Khalid; Iftikhar Hussain; Abdur Rehman Babar; Rashid Nawaz; Razaullah Khan; Waqas Saleem

doi:10.3390/ma13194327

Experimental Investigation and Statistical Evaluation of Optimized Cutting Process Parameters and Cutting Conditions to Minimize Cutting Forces and Shape Deviations in Al6026-T9

Materials (Basel). 2020 Sep 29;13(19):4327. doi: 10.3390/ma13194327.

Authors

Muhammad Abas¹, Bashir Salah², Qazi Salman Khalid¹, Iftikhar Hussain¹, Abdur Rehman Babar¹, Rashid Nawaz¹, Razaullah Khan³, Waqas Saleem⁴

Affiliations

¹ Department of Industrial Engineering, University of Engineering and Technology, Peshawar 25120, Pakistan.
² Industrial Engineering Department, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia.
³ Department of Mechanical Engineering Technology, University of Technology, Nowshera 24100, Pakistan.
⁴ Department of Mechanical and Manufacturing Engineering, Institute of Technology, F91 YW50 Sligo, Ireland.

Abstract

Precise, economical and sustainable cutting operations are highly desirable in the advanced manufacturing environment. For this aim, the present study investigated the influence of cutting parameters (i.e., the cutting speed (c), feed rate (f), depth of cut (d) and positive rake angle (p)) and sustainable cutting conditions (dry and minimum quantity lubricant (MQL)) on cutting forces (i.e., feed force (F_f), tangential forces (F_t), radial force (F_r) and resultant cutting forces (F_c) and shape deviations (i.e., circularity and cylindricity) of a 6026-T9 aluminum alloy. The type of lubricant and insert used are virgin olive oil and uncoated tungsten carbide tool. Turning experiments were performed on a TAKISAWA TC-1 CNC lathe machine and cutting forces were measured with the help of a Kistler 9257B dynamometer. Shape deviations were evaluated by means of a Tesa Micro-Hite 3D DCC 474 coordinate measuring machine (CMM). Experimental runs were planned based on Taguchi mixture orthogonal array design L16. Analysis of variance (ANOVA) was performed to study the statistical significance of cutting parameters. Taguchi based signal to noise (S/N) ratios are applied for optimization of single response, while for optimization of multiple responses Taguchi based signal to noise (S/N) ratios coupled with multi-objective optimization on the basis of ratio analysis (MOORA) and criteria importance through inter-criteria correlation (CRITIC) are employed. ANOVA results revealed that feed rate, followed by a depth of cut, are the most influencing and contributing factors for all components of cutting forces (F_f, F_t, F_r, and F_c) and shape deviations (circularity and cylindricity). The optimized cutting parameters obtained for multi responses are c = 600 m/min, f = 0.1 mm/rev, d = 1 mm and p = 25°, while for cutting conditions, MQL is optimal.

Keywords: aluminum alloy; analysis of variance (ANOVA); criteria importance through inter-criteria correlation (CRITIC); cutting forces; minimum quantity lubricant (MQL); multi-objective optimization based on ratio analysis (MOORA); shape deviations; taguchi orthogonal array design.

Grants and funding

RSP-2020/145/Deanship of Scientific Research, King Saud University, Saudi Arabia