Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel

Tool life prediction is an important factor that has profound influence on the higher productivity in industrial activities. High metal removal rate is intended to reduce the manufacturing cost and operation time. The productivity interms of a machining operation and machining cost, as well as qu...

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Main Authors:	Lajis, M. Amri, Amin, A. K. M. Nurul, Karim, A.N. Mustafizul, Hafiz, Khaled
Format:	Book Chapter
Language:	English
Published:	IIUM Press 2011
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://irep.iium.edu.my/23602/ http://irep.iium.edu.my/23602/ http://irep.iium.edu.my/23602/4/chp23.pdf

id	iium-23602
recordtype	eprints
spelling	iium-236022012-09-12T06:19:42Z http://irep.iium.edu.my/23602/ Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel Lajis, M. Amri Amin, A. K. M. Nurul Karim, A.N. Mustafizul Hafiz, Khaled TJ Mechanical engineering and machinery Tool life prediction is an important factor that has profound influence on the higher productivity in industrial activities. High metal removal rate is intended to reduce the manufacturing cost and operation time. The productivity interms of a machining operation and machining cost, as well as quality assurance, and the quality of the workpiece machined surface and its integrity are strongly depend on tool wear and consequently it depends on the life of the tool. Moreover, despite having the target of achieving optimum superficial finishing with the shortest possible time one must take into account the consideration of tool life, so that the complete finishing operation can be carried out with just one tool, avoiding the intermediate stops in order to change the tool due to its wear [1] Eventually, sudden failure of cutting tools lead to loss of productivity, rejection of parts and consequential economic losses [2] There are various methodologies and strategies that were adopted by researchers in order to predict tool wear or tool life in milling and turning. Response surface methodology (RSM) which is classified into designed experiments approach seems to be the most wide-spread methodology for the surface roughness prediction. RSM is an important methodology used in developing new processes, optimizing their performance, and improving the design and/or formulation of new products. [3] It is a dynamic and foremost important tool of design of experiment (DOE), wherein the relationship between responses of a process with its input decision variables is mapped to achieve the objective of maximization or minimization of the response properties. Many researchers have used RSM for their experimental design and analysis of the results in end milling, but very few of them were engaged in machining hard material which is commonly known as hard milling. Vivancos [4] presented a model for the prediction of surface roughness in high-speed side milling of hardened die steels. Palanisamy et al. [2] predicted the response variable tool wear based on DOE combined with RSM technique in a universal milling machine on AISI 1020 steel using carbide insert. The development of a surface roughness model for end milling EN32 casehardening carbon steel (160 BHN steel) using design of experiments and RSM was discussed by Mansor & Abdalla [5] As has been seen here, the most work done exclusively in milling of carbon steel where the hardness values are less than 40 HRC. IIUM Press 2011 Book Chapter PeerReviewed application/pdf en http://irep.iium.edu.my/23602/4/chp23.pdf Lajis, M. Amri and Amin, A. K. M. Nurul and Karim, A.N. Mustafizul and Hafiz, Khaled (2011) Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel. In: Advanced Machining Towards Improved Machinability of Difficult-to-Cut Materials. IIUM Press, Kuala Lumpur, Malaysia, pp. 175-179. ISBN 9789674181758 http://rms.research.iium.edu.my/bookstore/default.aspx
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Lajis, M. Amri Amin, A. K. M. Nurul Karim, A.N. Mustafizul Hafiz, Khaled Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel
description	Tool life prediction is an important factor that has profound influence on the higher productivity in industrial activities. High metal removal rate is intended to reduce the manufacturing cost and operation time. The productivity interms of a machining operation and machining cost, as well as quality assurance, and the quality of the workpiece machined surface and its integrity are strongly depend on tool wear and consequently it depends on the life of the tool. Moreover, despite having the target of achieving optimum superficial finishing with the shortest possible time one must take into account the consideration of tool life, so that the complete finishing operation can be carried out with just one tool, avoiding the intermediate stops in order to change the tool due to its wear [1] Eventually, sudden failure of cutting tools lead to loss of productivity, rejection of parts and consequential economic losses [2] There are various methodologies and strategies that were adopted by researchers in order to predict tool wear or tool life in milling and turning. Response surface methodology (RSM) which is classified into designed experiments approach seems to be the most wide-spread methodology for the surface roughness prediction. RSM is an important methodology used in developing new processes, optimizing their performance, and improving the design and/or formulation of new products. [3] It is a dynamic and foremost important tool of design of experiment (DOE), wherein the relationship between responses of a process with its input decision variables is mapped to achieve the objective of maximization or minimization of the response properties. Many researchers have used RSM for their experimental design and analysis of the results in end milling, but very few of them were engaged in machining hard material which is commonly known as hard milling. Vivancos [4] presented a model for the prediction of surface roughness in high-speed side milling of hardened die steels. Palanisamy et al. [2] predicted the response variable tool wear based on DOE combined with RSM technique in a universal milling machine on AISI 1020 steel using carbide insert. The development of a surface roughness model for end milling EN32 casehardening carbon steel (160 BHN steel) using design of experiments and RSM was discussed by Mansor & Abdalla [5] As has been seen here, the most work done exclusively in milling of carbon steel where the hardness values are less than 40 HRC.
format	Book Chapter
author	Lajis, M. Amri Amin, A. K. M. Nurul Karim, A.N. Mustafizul Hafiz, Khaled
author_facet	Lajis, M. Amri Amin, A. K. M. Nurul Karim, A.N. Mustafizul Hafiz, Khaled
author_sort	Lajis, M. Amri
title	Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel
title_short	Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel
title_full	Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel
title_fullStr	Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel
title_full_unstemmed	Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel
title_sort	modelling of tool life by response surface methodology in hard milling of aisi d2 tool steel
publisher	IIUM Press
publishDate	2011
url	http://irep.iium.edu.my/23602/ http://irep.iium.edu.my/23602/ http://irep.iium.edu.my/23602/4/chp23.pdf
first_indexed	2023-09-18T20:35:40Z
last_indexed	2023-09-18T20:35:40Z
_version_	1777409028421320704

Modelling of tool life by response surface methodology in hard milling of AISI D2 tool steel

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