Skip to main content
SpringerLink
Log in

An optimization method of the machining parameters in high-speed machining of stainless steel using coated carbide tool for best surface finish

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

High-speed machining (HSM) has emerged as a key technology in rapid tooling and manufacturing applications. Compared with traditional machining, the cutting speed, feed rate has been great progress, and the cutting mechanism is not the same. HSM with coated carbide cutting tools used in high-speed, high temperature situations and cutting more efficient and provided a lower surface roughness. However, the demand for high quality focuses extensive attention to the analysis and prediction of surface roughness and cutting force as the level of surface roughness and the cutting force partially determine the quality of the cutting process. This paper presents an optimization method of the machining parameters in high-speed machining of stainless steel using coated carbide tool to achieve minimum cutting forces and better surface roughness. Taguchi optimization method is the most effective method to optimize the machining parameters, in which a response variable can be identified. The standard orthogonal array of L9 (34) was employed in this research work and the results were analyzed for the optimization process using signal to noise (S/N) ratio response analysis and Pareto analysis of variance (ANOVA) to identify the most significant parameters affecting the cutting forces and surface roughness. For such application, several machining parameters are considered to be significantly affecting cutting forces and surface roughness. These parameters include the lubrication modes, feed rate, cutting speed, and depth of cut. Finally, conformation tests were carried out to investigate the improvement of the optimization. The result showed a reduction of 25.5% in the cutting forces and 41.3% improvement on the surface roughness performance.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Rama Kotaiah K, Srinivas J, Babu KJ, Srinivas K (2010) Prediction of optimal cutting states during inward turning: an experimental approach. Mater Manuf Processes 25(6):432–441, 1532–2475

    Article  Google Scholar 

  2. Anthony Xavior M, Adithan M (2009) Determining the influence of cutting fluids on tool wear and surface roughness during turning of AISI 304 austenitic stainless steel. J Mater Process Technol 209:900–909

    Article  Google Scholar 

  3. Dhar NR, Kamruzzaman M, Ahmed M (2006) Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel. J Mater Process Technol 172:299–304

    Article  Google Scholar 

  4. Ezugwu EO, Bonney J, Fadare DA, Sales WF (2005) Machining of nickel-base, Inconel 718, alloy with ceramic tools under finishing conditions with various coolant supply pressures. J Mater Process Technol 162–163:609–614

    Article  Google Scholar 

  5. Isik Y (2007) Investigating the machinability of tool steels in turning operations. Mater Des 28:1417–1424

    Article  Google Scholar 

  6. Teicher U, Künanz K, Ghosh A, Chattopadhyay AB (2008) Performance of diamond and CBN single-layered grinding wheels in grinding titanium. Mater Manuf Processes 23(3):224–227, 1532–2475

    Article  Google Scholar 

  7. Noordin MY, Venkatesh VC, Chan CL, Abdullah A (2001) Performance evaluation of cemented carbide tools in turning AISI 1010 steel. J Mater Process Technol 116:16–21

    Article  Google Scholar 

  8. Zafer T, Sezgin Y (2004) Investigation of the cutting parameters depending on process sound during turning of AISI 304 austenitic stainless steel. Mater Des 25:507–513

    Article  Google Scholar 

  9. Thepsonthi T, Hamdi M, Mitsui K (2009) Investigation into minimal-cutting-fluid application in high-speed milling of hardened steel using carbide mills. Int J Mach Tools Manuf 49:156–162

    Article  Google Scholar 

  10. Sayit E, Aslantas K, Çiçek A (2009) Tool wear mechanism in interrupted cutting conditions. Mater Manuf Processes 24(4):476–483, 1532–2475

    Article  Google Scholar 

  11. Klocke F, Einesblatter G (1997) Dry cutting. Annals CIRP 46:519–526

    Article  Google Scholar 

  12. Ming C, Fanghong S, Haili W, Renwei Y, Zhenghong Q, Shuqiao Z (2003) Experimental research on the dynamic characteristics of the cutting temperature in the process of high-speed milling. J Mater Process Technol 138:468–471

    Article  Google Scholar 

  13. Liu CS, Zhao B, Gao GF, Jiao F (2002) Research on the characteristics of the cutting force in the vibration cutting of a particle-reinforced metal matrix composites SiCp/Al. J Mater Process Technol 129:196–199

    Article  Google Scholar 

  14. Da Silva MB, Wallbank J (1999) Cutting temperature: prediction and measurement methods—a review. J Mater Process Technol 88:195–202

    Article  Google Scholar 

  15. Kundrák J, Mamalis AG, Gyáni K, Markopoulos A (2006) Environmentally friendly precision machining. Mater Manuf Processes 21(1):29–37, 1532–2475

    Article  Google Scholar 

  16. Kurniawan D, Yusof NM, Sharif S (2010) Hard machining of stainless steel using wiper coated carbide: tool life and surface integrity. Mater Manuf Processes 25(6):370–377, 1532–2475

    Article  Google Scholar 

  17. Paulo Davim J, Sreejith PS, Silva J (2007) Turning of brasses using minimum quantity of lubricant (MQL) and flooded lubricant conditions. Mater Manuf Processes 22(1):45–50, 1532–2475

    Article  Google Scholar 

  18. Varadarajan AS, Philip PK, Ramamoorthy B (2002) Investigation on hard turning with minimal cutting fluid application (HTMF) and its comparison with dry and wet turning. Int J Mach Tools Manuf 42:193–200

    Article  Google Scholar 

  19. Ghani JA, Choudhury IA, Hassan HH (2004) Application of Taguchi method in the optimization of end milling. J Mater Process Technol 145:84–92

    Article  Google Scholar 

  20. Abou-El-Hossein KA (2008) Cutting fluid efficiency in end milling of AISI stainless steel. Ind Lubric Tribol 60:115–120

    Article  Google Scholar 

  21. Gandarias A, de Luis Norberto Lopez L, Aizpitarte X, Lamikiz A (2008) Study of the performance of the turning and drilling of austenitic stainless steels using two coolant techniques. Int J Mach Mach Mater 3:1–17

    Google Scholar 

  22. Taguchi G (1990) Introduction to quality engineering. Asian Productivity Organization, Tokyo

    Google Scholar 

  23. Zhang JZ, Chen JC, Kirby ED (2007) Surface roughness optimization in an end-milling operation using the Taguchi design method. J Mater Process Technol 184:233–239

    Article  Google Scholar 

  24. Park SH (1996) Robust design and analysis for quality engineering. Chapman & Hall, London

    Google Scholar 

  25. Phadke MS (1989) Quality engineering using robust design. Prentice Hall, Englewood Cliffs, NJ

    Google Scholar 

  26. Suresh Kumar Reddy N, Venkateswara Rao P (2005) Performance improvement of end milling using graphite as a solid lubricant. Mater Manuf Processes 20(4):673–686, 1532–2475

    Article  Google Scholar 

  27. Khan MMA, Dhar NR (2006) Performance evaluation of minimum quantity lubrication by vegetable oil in terms of cutting force, cutting zone temperature, tool wear, job dimension and surface finish in turning AISI-1060 steel. J Zhejiang University 7:1790–1799

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Engineering Design and Manufacture, University of Malaya, Faculty of Engineering Building, 50603, Kuala Lumpur, Malaysia

    Ahmad Hamdan, Ahmed A. D. Sarhan & Mohd Hamdi

Authors
  1. Ahmad Hamdan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ahmed A. D. Sarhan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Mohd Hamdi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Ahmed A. D. Sarhan.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Hamdan, A., Sarhan, A.A.D. & Hamdi, M. An optimization method of the machining parameters in high-speed machining of stainless steel using coated carbide tool for best surface finish. Int J Adv Manuf Technol 58, 81–91 (2012). https://doi.org/10.1007/s00170-011-3392-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-011-3392-5

Keywords

Search

Navigation