440 C طريقة التحسين الاحصائي في عملية خرائط الفولاذ المقاوم للصدأ
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2022-05-31
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Abstract
The metal AISI 440 C is used in the manufacture of many important mechanical parts such as bearings, steam and water valves, pumps, turbines, compressor components, shafts, tableware, surgical instruments, nuclear applications, and other applications that require high strength and high corrosion resistance. On the other hand, many factors control the metal cutting processes, and one of these processes is orthogonal cutting. Therefore, this study focuses on how to find the optimal values of the turning machining process when operating this metal on the CNC lathe machine with and without using cooling fluids (dry and wet cutting) using the Design-Expert program. The experimental work included the preparation of seventeen different experiments conducted to collect data to implement the optimization process. Experiments were conducted by changing the levels of cutting (cutting speed, feed rate, and cutting depth) in a CNC lathe. The roughness of the cut was adopted as an indicator of the surface quality. The temperatures in the cutting zone were calculated, and also calculate the material removal rate to obtain the best results. Experimental equations were found using Box-Behnken technology in the Design-Expert program for each of the surface roughness, temperatures, and metal removal rate for workpieces. These equations were used to find the optimal cutting factors for speed, feeding rate, and the depth of the cut utilizing the response surface technique. Moreover, the Deform (2D) software in the finite element method (FEM) was used for cutting simulation and thermal cutting analysis. The effects of cutting factors on roughness, temperature, and rate of metal removal were analyzed statistically by (ANOVA).
The findings of the analysis showed that in the dry conditions, the influence of input parameters on responses was observed as follows: surface roughness (feed: 69.37%, depth of cut 28.68%, and speed 1.95%), temperature (feed: 8.06%, depth of cut: 91.9%, and speed: 0.04%), and material removal rate (feed: 73.46%, depth of cut: 11.97%, and speed: 14.57%). While the influence of parameters in wet case were: surface roughness (feed:68.84%, depth of cut: 4.36%, speed: 26.84%), temperature (feed:1.21%, depth of cut: 94,14%, and speed: 4.65%), and material removal rate (feed: 37.09%, depth of cut: 35.35%, and speed: 27.56%).