Application of grey relational analysis based on Taguchi method for optimizing machining parameters in hard turning of high chrome cast iron

Abstract

High chrome white cast iron is particularly preferred in the production of machine parts requiring high wear resistance. Although the amount of chrome in these materials provides high wear and corrosion resistances, it makes their machinability difficult. This study presents an application of the grey relational analysis based on the Taguchi method in order to optimize chrome ratio, cutting speed, feed rate, and cutting depth for the resultant cutting force (F _R) and surface roughness (R _a) when hard turning high chrome cast iron with a cubic boron nitride (CBN) insert. The effect levels of machining parameters on F _R and R _a were examined by an analysis of variance (ANOVA). A grey relational grade (GRG) was calculated to simultaneously minimize F _R and R _a. The ANOVA results based on GRG indicated that the feed rate, followed by the cutting depth, was the main parameter and contributed to responses. Optimal levels of parameters were found when the chrome ratio, cutting speed, feed rate, and cutting depth were 12%, 100 m/min, 0.05 mm/r, and 0.1 mm, respectively, based on the multiresponse optimization results obtained by considering the maximum signal to noise (S/N) ratio of GRG. Confirmation results were verified by calculating the confidence level within the interval width.

Keywords

High chrome cast iron / Hard turning / Grey relational analysis / Multi-response optimization / Taguchi method

References

[1] Chung RJ, Tang X, Hinckley DYLB, et al. Microstructure refinement of hypereutetic high Cr cast iron using hard carbide-forming elements for improved wear resistance. Wear, 2013, 301: 695-706.

[2] Çetinkaya C. An investigation of the wear behaviour of white cast irons under different compositions. Mater Des, 2006, 27: 437-445.

[3] El-Aziz KA, Zohdy K, Saber D, et al. Wear and corrosion behavior of high-Cr white cast iron alloys in different corrosive media. J Bio Tribo Corros, 2015, 1: 25.

[4] Sallam HEM, El-Aziz KA, El-Raouf HA, et al. Failure analysis and flexural behavior of high chromium white cast iron and AISI4140 Steel bimetal beams. Mater Des, 2013, 52: 974-980.

[5] Günay M, Korkmaz ME, Yaşar N. Finite element modeling of tool stresses on ceramic tools in hard turning. Mechanika, 2017, 23(3): 432-440.

[6] Zhou JM, Andersson M, Stahl JE. Identification of cutting error in precision hard turning process. J Mater Process Technol, 2004, 153: 746-750.

[7] Klocke F, Brinksmeier E, Weinert K. Capabilty profile of hard cutting and grinding process. CIRP Ann Manuf Technol, 2005, 54: 22-45.

[8] Smith S, Melkote SN, Curzio EL, et al. Effect of surface integrity of hard turned AISI 52100 steel on fatigue performance. Mater Sci Eng A, 2007, 459: 337-346.

[9] Fallbohmer P, Rodriguez CA, Ozel T, et al. High-speed machining of cast iron and alloy steel for die and mould manufacturing. J Mater Process Technol, 2000, 98: 104-115.

[10] Aslan E, Camuscu N, Birgören B. Design optimisation of cutting parameter when turning hardened AISI 4140 steel (63 HRC) with Al₂O₃ + TiCN mixed ceramic tool. Mater Des, 2007, 28: 1618-1622.

[11] Huang Y, Chou YK, Liang SY. CBN tool wear in hard turning: a survey on research progresses. Int J Adv Manuf Technol, 2007, 35: 443-453.

[12] Sing D, Rao PV. A surface roughness prediction model for hard turning process. Int J Adv Manuf Technol, 2006, 32: 1115-1124.

[13] Çoğun C, Özses B. Bilgisayar sayisal denetimli takim tazgahlarinda değişik işleme koşullarinin yüzey pürüzlülüğüne etkisi. J Fac Eng Arch Gazi Univ, 2002, 17(1): 59-75.

[14] Korkmaz ME, Günay M. Finite element modelling of cutting forces and power consumption in turning of AISI 420 martensitic stainless steel. Arab J Sci Eng, 2018.

[15] Bartarya G, Choudhury SK. Effect of cutting parametes on cutting force and surface roughness during finish hard turning AISI52100 grade steel. Procedia CIRP, 2012, 1: 651-656.

[16] Rao CJ, Rao DN, Srihari P. Influence of cutting parameters on cutting force and surface finish in turning operation. Procedia Eng, 2013, 64: 1405-1415.

[17] Rafai NH, Islam MN. An investigation in to dimensional accuracy and surface finish achieveble in dry turning. Mach Sci Technol, 2009, 13: 571-589.

[18] Bouacha K, Yallese MA, Mabrouki T, et al. Statistical analysis of surface roughness and cutting force using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool. Int J Refract Met Hard Mater, 2010, 28: 349-361.

[19] Chavoshi SZ, Tajdari M. Surface roughness modelling in hard turning operation of AISI 4140 using CBN cutting tool. Int J Mater Form, 2010, 3: 233-239.

[20] Masood SH, Armitage K, Brandt M. An experimental study of laser-assisted machining of hard-to-wear white cast iron. Int J Mach Tool Manuf, 2011, 51: 450-456.

[21] Ravi AM, Murigendrappa SM, Mukunda PG. Machinability investigation on high chrome white cast iron using multicoated hard carbide tools. Trans Indian Inst Met, 2014, 67(4): 485-502.

[22] Jiang W, More AS, Brown WD, et al. A CBN-TiN composite coating for carbide insert: coating characterisation and its application for finish hard turning. Surf Coat Technol, 2006, 201: 2443-2449.

[23] Manivel D, Gandhinathan R. Optimization of surface roughness and tool wear in hard turning of austempered ductile iron using Taguchi method. Meas, 2016, 93: 108-116.

[24] Kır D, Öktem H, Çöl M, et al. Determination of the cutting tool performance of high-alloyed white cast iron (Ni-Hard 4) using the Taguchi method. Mater Technol, 2016, 50(2): 239-246.

[25] KYOCERA Precision Tools, Inc. http://www.kyoceraprecisiontools.com/indexable/pdf/Turning_Catalog_2017.pdf. Accessed 16 Jan 2017

[26] Taguchi G, Chowdhury S, Wu Y. Taguchi’s quality engineering handbook, 2004, Hoboken: Wiley.

[27] Sarıkaya M, Güllü A. Multiresponse optimization of minimum quantity lubrication parameter using Taguchi-based grey relational analysis in turning of difficult-to-cut alloy Haynes 25. J Clean Prod, 2015, 91: 347-357.

[28] Deng JL. Introduction to grey system theory. J Grey Syst, 1989, 1: 1-24.

[29] Sahoo AK, Sahoo B. Performance studies of multilayer hard surface coating (TiN/TiCN/Al₂O₃/TiN) of indexeble carbide insert in hard machining: part-II (RSM, grey relational and techno economical approach). Measurement, 2013, 46: 2868-2884.

[30] Kalyon A, Özyürek D, Günay M, et al. Dry sliding wear behaviour of valve seat insert produced from high chromium white iron. High Temp Mater Process, 2015, 34: 635-641.

[31] Grzesik W, Rech J, Wanat T. Surface finish on hardened bearing steel part produced by superhard and abrasive tools. Int J Mach Tools Manuf, 2007, 47: 255-262.

[32] Savaş V, Ozay C, Ballikaya H. Experimental investigation of cutting parameter in machining of 100Cr6 with tangential turnmilling method. Adv Manuf, 2016, 4: 97-104.

Funding

Karabük University(KBÜ-BAP-13/1-DR-007)