A Comparative Study on CNC Turning of S32750 Super Duplex Stainless Steel with Novel Dual Textured Tool Inserts with Untextured Tool Inserts for Improving Material Removal Rate and Surface Roughness Under Nano Minimum Quantity Lubrication Condition

Q4 Materials Science NanoWorld Journal Pub Date : 2023-10-05 DOI:10.17756/nwj.2023-s3-033
Pandurangan Bhathavachalam, Murugaiyan Thiyagu
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Abstract

This research involves a comparative study between novel dual-textured tool inserts and untextured tool inserts during CNC turning of S32750 super duplex stainless steel (SDSS), with a specific focus on nano-Minimum Quantity Lubrication (nMQL) conditions. The primary aim is to optimize the Material Removal Rate (MRR) and surface finish through a comprehensive analysis of the performance exhibited by these two categories of tool inserts. Surface texturing is an innovative green manufacturing technology that enhances the wettability of the cutting fluid at the cutting edge by modifying the surface texture of the cutting tool at the rake face. A novel dual textured tool with square and linear groove texture patterns is engraved on the tool surface using a femtosecond laser technique. The MRR and workpiece quality of a Jobber XL CNC turner used for turning operations on S32750 SDSS employing dual-textured tool inserts and untextured tool inserts were compared. In this study, each group (Control and experimental) is composed of 20 samples, yielding a cumulative sample size of 40. The calculation of the sample size is performed with a statistical power (G-power) of 80% and a significance level (alpha) set to 0.0024. The experimental results show an average surface roughness of 1.276 μm for dual-textured tools and 1.072 μm for untextured tools when turning S32750 SDSS rod. A better MRR of 13.126 cc/min is obtained when turning with dual-textured tools when compared to 10.846 cc/min with an untextured tool insert. The independent t-test results in the CNC turning process with nMQL machining conditions are statistically significant for surface roughness with a “p” value (2-tailed) of 0.001 (p < 0.05) and for MRR data, it is p = 0.0074 (p < 0.05). Based on the findings of this experimental investigation, the application of the proposed dual-textured tool insert resulted in a significant augmentation of the MRR by 17.12%, coupled with a corresponding reduction in surface roughness by 19.35%, in comparison to the utilization of the untextured carbide tool inserts.
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使用新型双纹理刀片和无纹理刀片对 S32750 超级双相不锈钢进行数控车削以提高纳米最小量润滑条件下的材料去除率和表面粗糙度的比较研究
本研究涉及在 S32750 超级双相不锈钢 (SDSS) 的数控车削过程中,对新型双纹理刀具刀片和无纹理刀具刀片进行比较研究,特别关注纳米最小量润滑 (nMQL) 条件。主要目的是通过全面分析这两类刀片的性能,优化材料去除率(MRR)和表面光洁度。表面纹理加工是一种创新的绿色制造技术,它通过改变切削刀具前刀面的表面纹理来提高切削液在切削刃处的润湿性。利用飞秒激光技术在刀具表面雕刻出具有方形和线形沟槽纹理图案的新型双纹理刀具。比较了使用双纹理刀具刀片和未纹理刀具刀片对 S32750 SDSS 进行车削加工的 Jobber XL 数控车床的 MRR 和工件质量。在本研究中,每组(对照组和实验组)由 20 个样本组成,累计样本量为 40 个。在计算样本量时,统计能力(G-power)为 80%,显著性水平(alpha)设为 0.0024。实验结果表明,在车削 S32750 SDSS 棒材时,双纹理刀具的平均表面粗糙度为 1.276 μm,无纹理刀具的平均表面粗糙度为 1.072 μm。在车削 S32750 SDSS 棒材时,使用双纹理刀具的 MRR 为 13.126 cc/min,而使用无纹理刀具的 MRR 为 10.846 cc/min。在采用 nMQL 加工条件的 CNC 车削过程中,表面粗糙度的独立 t 检验结果具有统计学意义,"p "值(双尾)为 0.001(p < 0.05),而 MRR 数据的独立 t 检验结果为 p = 0.0074(p < 0.05)。根据这项实验调查的结果,与使用无纹理硬质合金刀片相比,使用拟议的双纹理刀片可显著提高 17.12% 的 MRR,同时相应降低 19.35% 的表面粗糙度。
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来源期刊
NanoWorld Journal
NanoWorld Journal Materials Science-Polymers and Plastics
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