Experimental investigation of efficiency of machining performance for difficult to cut materials under different cutting conditions

國 立 高 雄 科 技 大 學 機械工程系博士班 博士論文 不同切削條件下難切削材料加工性能效率的實驗研究 Experimental Investigation of Efficiency of Machining Performance for Difficult-to-cut Materials under Different Cutting Conditions 研究生 ： 武育簡 指導教授 ： 黃世疇 教授 中華民國 109 年 12 月 不同切削條件下難切削材料加工性能效率的實驗研究 Experimental Investigation of Efficiency of Machining Performance for Difficult-to-cut Materials under Different Cutting Conditions Ngoc-Chien Vu 學生：武育簡 Shyh-Chour Huang 指導教授：黃世疇 國 立 高 雄 科 技 大 學 機械工程系博士班 博士論文 A dissertation Submitted to Department of Mechanical Engineering National Kaohsiung University of Science and Technology in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy in Mechanical Engineering December, 2020 Kaohsiung, Taiwan, Republic of China 中華民國 109 年 12 月 i ii 不同切削條件下難切削材料加工性能效率的實驗研究 研究生：武育簡 指導教授：黃世疇 教授 國立高雄科技大學 機械工程系博士班 摘 要 近年來，科學界發現越來越多具有優異特性的新材料能夠滿足抵抗極端工作 條件的設計要求。新材料具有獨特的冶金特徵，並帶來新的加工挑戰，使其難以 切削。難切削材料的加工給研究人員帶來巨大挑戰，這些困難可能與添加的硬質 成分磨蝕性或原始材料的強度，韌性，腐蝕或耐熱性提高有關。研究人員一直在 尋找合適的切削刀具，適當的加工參數與技術，以利於機械加工。為了改善此類 材料的可加工性與切削條件，本論文旨在探討，建模與最佳化此類材料中的硬化 鋼與超級合金。 本論文包括四個部分，第一部分是對 AISI H13 硬銑削材料的最佳化研究，以 於乾切削條件下獲得最大的表面粗糙度與切削力輸出。三個輸入是切削速度，進 給速度與切削軸向深度，兩個輸出是切削力與表面粗糙度，研究中以方差分析 （ANOVA）分析加工參數（切削速度，進給速度與切削軸向深度）對響應參數 （切削力，表面粗糙度）的影響。結果顯示，表面粗糙度與切削力的最佳值分別 為 0.206 µm 與 66.58N。相對應的輸入值為切削速度為 100 m / min，進給速度為 0.015 mm /齒，切削深度為 0.44 mm。 i 在結果的第二部分中，結果顯示具有 Al2O3 納米粒子的納米流體在 AISI H13 鋼的硬銑削中具有顯著的性能，研究中使用田口方法找到最佳的冷卻條件與切削 參數最佳值，分析結果顯示，納米流體的性能可以降低切削力與切削溫度，提高 表面光潔度和工具壽命。 在結果的第三部分中，對 AISI H13 鋼於具有石墨納米顆粒的最低質量潤滑劑 下的硬銑削加工進行多目標最佳化。切削速度，齒進給量，切削深度與工件硬度 視為加工參數，而表面粗糙度，切削能量，切削溫度與材料去除率則被視為技術 響應。研究結果顯示，與最壞情況相比，切割能量最多可降低 14％，適當選擇加 工參數可以提高加工生產率與能源效率。 在結果的第四部分中，為了改善 Inconel-800 超級合金的切削條件，研究中使 用懸浮納米顆粒增強最小量的潤滑。結果顯示，RSM 模型與 NSGA-II 組合起來的 應用適合本研究。由於多目標最佳化可提供多種解決方案，因此採用 Pareto 圖和 數據挖掘來探討加工參數的選擇，既可以節省時間和成本，又可以提高能源效率， 同時提高生產率和表面質量。結果顯示，切削能量比與能耗分別降低了 20.2％與 6.4％。 關鍵字：難切削材料，加工最佳化，節能，環保意識加工，納米流體 MQL，加工 性能 ii Experimental Investigation of Efficiency of Machining Performance for Difficult-to-cut Materials under Different Cutting Conditions Student: Ngoc-Chien Vu Advisor: Shyh-Chour Huang Department of Mechanical Engineering National Kaohsiung University of Science and Technology Abstract In recent years, with the unlimited efforts of science and technology, more and more new materials with exceptional characteristics are being found to meet design requirements that resist extreme working conditions The new materials have unique metallurgical features and lead to new machining challenges, which make them difficult to cut The processing of difficult-to-cut materials always dramatically challenges for researchers and toolmakers These difficulties can be related to the abrasive nature of the added hard constituents or the improved strength, toughness, corrosion, or temperature resistance of the original material Researchers are always searching to find suitable cutting tools, adequate process parameters, and techniques to facilitate machining to defeat the ongoing challenges To improve the machinability and cutting conditions for difficult-to-cut materials, this study aims to investigate, model, and optimize for hardened steels, and super-alloys with different cutting conditions and cutting parameters The results of this study consist of four parts The first part is a study of optimization in hard milling AISI H13 material to obtain maximum output for surface roughness and cutting force under dry cutting The three inputs are cutting speed, feed rate, and axial depth of cut, and the two outputs are cutting force and surface roughness Analysis of Variance (ANOVA) is adopted to analyze the effect of process parameters (cutting speed, feed rate, and axial depth of cut) on response parameters (cutting force, iii surface roughness) The results show that the optimal values for surface roughness and cutting force are 0.206 µm and 66.58 N, respectively Corresponds to that, input values are cutting speed of 100 m/min, feed rate of 0.015 mm/tooth, and depth of cut of 0.44 mm In the second part of the results, the noteworthy performance of nanofluid with Al2O3 nano-particle has been demonstrated for the hard milling of AISI H13 steel The Taguchi method was applied to find the best cooling condition and the optimal values of cutting parameters The research results indicate a promising performance of nanofluid wherein it can reduce cutting force and cutting temperature, enhance the surface finished, and tool life In the third part of the results, the multi-objective optimization of the hard milling process of AISI H13 steel under minimum quality lubricant with graphite nanoparticle was performed The cutting speed, feed per tooth, depth of cut, and hardness of workpiece were taken as the process parameters while surface roughness, cutting energy, cutting temperature, and material removal rate was considered as technological responses The research results show that cutting energy can be reduced up to around 14 % compared to the worst case and the appropriate selection of machining parameters can help to increase machining productivity and energy efficiency In the fourth part of the results, to improve the cutting conditions for Inconel-800 super-alloy, sustainable methods in which minimum quantity lubrication enhanced with suspended nanoparticles were employed The results indicate that the application of the RSM model in combination with NSGA-II is appropriate for this study Because multiobjective optimization gives multiple solutions, Pareto plot and data mining are employed to support the selection of process parameters that can save time and cost and increase energy efficiency, meanwhile, simultaneously improve productivity and surface quality The results show that the specific cutting energy and energy consumption can be reduced up to 20.2 % and 6.4 %, respectively Keywords: Difficult-to-cut materials, Machining optimization, Energy savings, Environmentally conscious machining, Nanofluid MQL, Machining performance iv Acknowledgments I would like to express the most profound gratefulness to my advisor, Prof Shyh-Chour Huang, for his supervision and aid during my research times at National Kaohsiung University of Science and Technology (NKUST), Taiwan He is always supportive and authorizes me to develop my understanding of the fields related to machining, compliant mechanism I would also like to express my thankfulness to Associate Professor, Dr Xuan-Phuong Dang, for his guidance, supports, and giving valuable advice for me in my study and research time at NKUST Next, I would like to thank Prof Jao-Hwa Kuang, Prof Tao-Hsing Chen, Prof Bo Wun Huang, Prof Jau-Wen Lin, and Prof Hsu ChaoMing for receiving to be the committee members for my dissertation defense I also extend my thanks to the Department of Mechanical Engineering of NKUST Especially the professors who advised and encouraged me with my study and research, Assistant Professor Ming-Chang Tsai, Assistant Professor Te-Ching Hsiao, and Assistant Professor Mau-Sheng Chen I also would like to give thanks to all of the members of the CAE A&D Laboratory, Department of Mechanical Engineering at National Kaohsiung University of Science and Technology They guided and assisted me when I joined research groups at the lab I would like to thank Dr Huu-That Nguyen, Dr The-Vinh Do, Dr Anh-Vu Le Nguyen, Dr Van-Nhat Nguyen, Dr Ngoc-Thai Huynh, Dr Xuan-Thang Trinh, Dr Hong-Xuyen Ho, Dr Hoang-Sa Dang, and Dr Dinh-Chien Dang who were NKUST alumni for assistants in the first days of my enrollment Thankfulness to their guidance, I was able to integrate into life in Taiwan and research progressed faster Besides, many thanks to the Vietnamese students who have been studying and researching at NKUST People who discussed and supported each other in study and life Moreover, I also would like to send my thanks to Prof Jinn-Jong Sheu and his student (Bao-Shan Wang) in the Precision metal forming and high-speed manufacturing v laboratory, they have been helped me with many things, as well as facilitating me to use the equipment The last thanks, it is essential for my family, for my venerable parents (my father, Mr Chuyen Vu Ngoc, my mother, Mrs Man Tran Thi, and my brother, Mr Duc Vu Ngoc) Especially for my darling wife, Mrs Bao Ngoc Nguyen Thi, my daughter (Thien Ha Vu Ngoc), and my son (Thien Phu Vu Ngoc) who is always with me and the encouragement for me to complete my studies in Taiwan Finally, my research has been sponsored by the Ministry of Science and Technology of Taiwan under Contract Number MOST 107-2622-E-992-013-362 CC3 and under Contract Number E0002B and the Ministry of Science and Technology of the Republic of China under Contract Number MOST 108-2622-E-992-009- CC3 Some parts of the dissertation have published in the papers titled: "Multiobjective optimization of hard milling process of AISI H13 in terms of productivity, quality, and cutting energy under nanofluid minimum quantity lubrication condition" and "Modeling and optimization of machining parameters in milling of INCONEL800 super alloy considering energy, productivity, and quality using nanoparticle suspended lubrication" in SCIE Journal of Measurement and Control, and "MultiObjective Optimization of Surface Roughness and Cutting Forces in Hard Milling Using Taguchi and Response Surface Methodology" in EI Journal of Key Engineering Materials vi Contents Abstract i Contents vii List of Tables x List of Figures xii Nomenclature xvi Chapter Introduction 1.1 Motivation of the study 1.2 Objective of the study 1.3 Scope of the study 1.4 Organization of the dissertation Chapter Background 2.1 Machining difficult-to-cut materials 2.1.1 Difficult-to-cut materials 2.1.2 Operations for machining difficult-to-cut materials 11 2.2 Cooling and lubrication method 14 2.2.1 Dry cutting 15 2.2.2 Near dry or MQL 16 2.2.3 Nanofluid MQL 19 2.3 Literature review 21 Chapter Research Method 29 3.1 Design of experiment (DOE) 29 vii References [1] M K Gupta and P Sood, "Machining 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Objective of the study The objective of the research is to study the machining of difficult- to- cut materials under various cutting conditions such as dry, MQL, nanofluids as well as different cutting. .. difficult- to- cut materials 2.1.1 Difficult- to- cut materials 2.1.2 Operations for machining difficult- to- cut materials 11 2.2 Cooling and lubrication method 14 2.2.1 Dry cutting