Drilling performance analysis on super duplex stainless steel (AISI 2507) using scalable pulse power plasma TiSiN- and AlTiN-coated tools and optimizing machining parameters through Taguchi–Fuzzy approach

IF 2.3 4区工程技术 Q2 ENGINEERING, MECHANICAL

Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering Pub Date : 2024-08-16 DOI:10.1177/09544089241270849

Prajwal Agrawal, Shivam Kenche, T Sampath Kumar

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Abstract

In recent years, super duplex stainless steel (SDSS) has gained a lot of importance due to its strength and excellent resistance to corrosion cracking for applications in marine and chemical processing industries, etc. In spite of various progress in the field, the drilling of SDSS leads to the formation of chips that are very strong and abrasive, which makes it challenging to have proper drilling. To overcome this issue by utilizing suitable parameters such as drill bit coating, environmental conditions and parameters for drilling. The SDSS machining output results were compared for both dry and minimum quantity lubrication (MQL) conditions using coated and uncoated drill bits. A scalable pulse power plasma (S3P) technique was utilized to deposit the titanium silicon nitride (TiSiN) and aluminum titanium nitride (AlTiN) coatings on solid carbide drill bits. In the experiments, three levels of drilling parameters have been chosen, including spindle speed (550, 700, 850 rpm), feed rate (0.035, 0.045, 0.060 m/min), and drill bit types. The experiment was designed using Taguchi's orthogonal L9 array. The influence of machining parameters such as cutting force, surface roughness, and circularity error were examined using variance analysis (ANOVA) and signal-to-noise (S/N) ratios. To enhance the drilling process parameters through a single comprehensive output measure, the obtained results were taken as an input to the fuzzy logic networks using multi-factor analysis. At the L7 trial, the least cutting force was observed at 525.7 N for dry conditions and 227.6 N for MQL conditions and gave cone-spiral and continuous chips. In order to analyze the signal-to-noise ratio effectively, high value correspond to better-quality characteristics. In accordance with ANOVA results pertaining to cutting force, a percentage contribution variance of 48.92% was obtained for the feed rate, which contributed to cutting force to a greater extent, followed by 36.82% for spindle speed and 14.19% for the type of drill bit.

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使用可扩展脉冲功率等离子体 TiSiN 和 AlTiN 涂层刀具对超级双相不锈钢（AISI 2507）进行钻孔性能分析，并通过田口-模糊法优化加工参数

近年来，超级双相不锈钢（SDSS）因其高强度和优异的抗腐蚀开裂性能，在船舶和化学加工等行业的应用中得到了广泛重视。尽管在这一领域取得了各种进展，但在对 SDSS 进行钻孔时，仍会形成非常坚固且易磨损的切屑，这给正确钻孔带来了挑战。为了克服这一问题，需要利用合适的参数，如钻头涂层、环境条件和钻孔参数。在使用有涂层和无涂层钻头时，比较了干润滑和最小量润滑（MQL）条件下的 SDSS 加工输出结果。利用可扩展脉冲功率等离子体（S3P）技术在整体硬质合金钻头上沉积氮化钛硅（TiSiN）和氮化铝钛（AlTiN）涂层。实验选择了三个钻孔参数，包括主轴转速（550、700、850 rpm）、进给速度（0.035、0.045、0.060 m/min）和钻头类型。实验采用田口 L9 正交阵列进行设计。利用方差分析（ANOVA）和信噪比（S/N）检验了切削力、表面粗糙度和圆度误差等加工参数的影响。为了通过单一的综合输出指标来提高钻孔工艺参数，利用多因素分析法将获得的结果作为模糊逻辑网络的输入。在 L7 试验中，干式条件下的最小切削力为 525.7 N，MQL 条件下的最小切削力为 227.6 N，并产生了锥螺旋和连续切屑。为了有效分析信噪比，高值对应于更好的质量特性。与切削力相关的方差分析结果显示，进给速率对切削力的贡献率为 48.92%，其次是主轴转速和钻头类型，分别为 36.82%和 14.19%。

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来源期刊

Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 工程技术-工程：机械

CiteScore

3.80

自引率

16.70%

发文量

370

审稿时长

6 months

期刊介绍： The Journal of Process Mechanical Engineering publishes high-quality, peer-reviewed papers covering a broad area of mechanical engineering activities associated with the design and operation of process equipment.