A Closer Look at Precision Hard Turning of AISI4340: Multi-Objective Optimization for Simultaneous Low Surface Roughness and High Productivity

This article reports an extended investigation into the precision hard turning of AISI 4340 alloy steel when machined by two different types of inserts: wiper nose and conventional round nose. It provides a closer look at previously published work and aims at determining the optimal process paramete...

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Veröffentlicht in:	Materials Jg. 15; H. 6; S. 2106
Hauptverfasser:	Abbas, Adel T., Al-Abduljabbar, Abdulhamid A., Alnaser, Ibrahim A., Aly, Mohamed F., Abdelgaliel, Islam H., Elkaseer, Ahmed
Format:	Journal Article
Sprache:	Englisch
Veröffentlicht:	Switzerland MDPI AG 12.03.2022 MDPI
Schlagworte:	Alloy steels Combustion chambers Cutting speed Feed rate Genetic algorithms Geometry Inserts Manufacturers Manufacturing Multiple objective analysis Nose Optimization techniques Pareto optimization Process parameters Productivity Researchers Robustness (mathematics) Search algorithms Steel alloys Surface properties Surface roughness Turning (machining) material removal rate multi-objective optimization AISI 4340 alloy steel wiper insert surface integrity surface quality
ISSN:	1996-1944, 1996-1944
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Abstract	This article reports an extended investigation into the precision hard turning of AISI 4340 alloy steel when machined by two different types of inserts: wiper nose and conventional round nose. It provides a closer look at previously published work and aims at determining the optimal process parameters for simultaneously minimizing surface roughness and maximizing productivity. In the mathematical models developed by the authors, surface roughness at different cutting speeds, depths of cut and feed rates is treated as the objective function. Three robust multi-objective techniques, (1) multi-objective genetic algorithm (MOGA), (2) multi-objective Pareto search algorithm (MOPSA) and (3) multi-objective emperor penguin colony algorithm (MOEPCA), were used to determine the optimal turning parameters when either the wiper or the conventional insert is used, and the results were experimentally validated. To investigate the practicality of the optimization algorithms, two turning scenarios were used. These were the machining of the combustion chamber of a gun barrel, first with an average roughness (Ra) of 0.4 µm and then with 0.8 µm, under conditions of high productivity. In terms of the simultaneous achievement of both high surface quality and productivity in precision hard turning of AISI 4340 alloy steel, this work illustrates that MOPSA provides the best optimal solution for the wiper insert case, and MOEPCA results are the best for the conventional insert. Furthermore, the results extracted from Pareto front plots show that the wiper insert is capable of successfully meeting both the requirements of Ra values of 0.4 µm and 0.8 µm and high productivity. However, the conventional insert could not meet the 0.4 µm Ra requirement; the recorded global minimum was Ra = 0.454 µm, which reveals the superiority of the wiper compared to the conventional insert.
AbstractList	This article reports an extended investigation into the precision hard turning of AISI 4340 alloy steel when machined by two different types of inserts: wiper nose and conventional round nose. It provides a closer look at previously published work and aims at determining the optimal process parameters for simultaneously minimizing surface roughness and maximizing productivity. In the mathematical models developed by the authors, surface roughness at different cutting speeds, depths of cut and feed rates is treated as the objective function. Three robust multi-objective techniques, (1) multi-objective genetic algorithm (MOGA), (2) multi-objective Pareto search algorithm (MOPSA) and (3) multi-objective emperor penguin colony algorithm (MOEPCA), were used to determine the optimal turning parameters when either the wiper or the conventional insert is used, and the results were experimentally validated. To investigate the practicality of the optimization algorithms, two turning scenarios were used. These were the machining of the combustion chamber of a gun barrel, first with an average roughness (Ra) of 0.4 µm and then with 0.8 µm, under conditions of high productivity. In terms of the simultaneous achievement of both high surface quality and productivity in precision hard turning of AISI 4340 alloy steel, this work illustrates that MOPSA provides the best optimal solution for the wiper insert case, and MOEPCA results are the best for the conventional insert. Furthermore, the results extracted from Pareto front plots show that the wiper insert is capable of successfully meeting both the requirements of Ra values of 0.4 µm and 0.8 µm and high productivity. However, the conventional insert could not meet the 0.4 µm Ra requirement; the recorded global minimum was Ra = 0.454 µm, which reveals the superiority of the wiper compared to the conventional insert. This article reports an extended investigation into the precision hard turning of AISI 4340 alloy steel when machined by two different types of inserts: wiper nose and conventional round nose. It provides a closer look at previously published work and aims at determining the optimal process parameters for simultaneously minimizing surface roughness and maximizing productivity. In the mathematical models developed by the authors, surface roughness at different cutting speeds, depths of cut and feed rates is treated as the objective function. Three robust multi-objective techniques, (1) multi-objective genetic algorithm (MOGA), (2) multi-objective Pareto search algorithm (MOPSA) and (3) multi-objective emperor penguin colony algorithm (MOEPCA), were used to determine the optimal turning parameters when either the wiper or the conventional insert is used, and the results were experimentally validated. To investigate the practicality of the optimization algorithms, two turning scenarios were used. These were the machining of the combustion chamber of a gun barrel, first with an average roughness (Ra) of 0.4 µm and then with 0.8 µm, under conditions of high productivity. In terms of the simultaneous achievement of both high surface quality and productivity in precision hard turning of AISI 4340 alloy steel, this work illustrates that MOPSA provides the best optimal solution for the wiper insert case, and MOEPCA results are the best for the conventional insert. Furthermore, the results extracted from Pareto front plots show that the wiper insert is capable of successfully meeting both the requirements of Ra values of 0.4 µm and 0.8 µm and high productivity. However, the conventional insert could not meet the 0.4 µm Ra requirement; the recorded global minimum was Ra = 0.454 µm, which reveals the superiority of the wiper compared to the conventional insert.This article reports an extended investigation into the precision hard turning of AISI 4340 alloy steel when machined by two different types of inserts: wiper nose and conventional round nose. It provides a closer look at previously published work and aims at determining the optimal process parameters for simultaneously minimizing surface roughness and maximizing productivity. In the mathematical models developed by the authors, surface roughness at different cutting speeds, depths of cut and feed rates is treated as the objective function. Three robust multi-objective techniques, (1) multi-objective genetic algorithm (MOGA), (2) multi-objective Pareto search algorithm (MOPSA) and (3) multi-objective emperor penguin colony algorithm (MOEPCA), were used to determine the optimal turning parameters when either the wiper or the conventional insert is used, and the results were experimentally validated. To investigate the practicality of the optimization algorithms, two turning scenarios were used. These were the machining of the combustion chamber of a gun barrel, first with an average roughness (Ra) of 0.4 µm and then with 0.8 µm, under conditions of high productivity. In terms of the simultaneous achievement of both high surface quality and productivity in precision hard turning of AISI 4340 alloy steel, this work illustrates that MOPSA provides the best optimal solution for the wiper insert case, and MOEPCA results are the best for the conventional insert. Furthermore, the results extracted from Pareto front plots show that the wiper insert is capable of successfully meeting both the requirements of Ra values of 0.4 µm and 0.8 µm and high productivity. However, the conventional insert could not meet the 0.4 µm Ra requirement; the recorded global minimum was Ra = 0.454 µm, which reveals the superiority of the wiper compared to the conventional insert.
Author	Elkaseer, Ahmed Aly, Mohamed F. Abbas, Adel T. Al-Abduljabbar, Abdulhamid A. Abdelgaliel, Islam H. Alnaser, Ibrahim A.
AuthorAffiliation	3 Department of Mechanical Engineering, Faculty of Engineering, Fayoum University, Fayoum 63514, Egypt 2 Department of Mechanical Engineering, School of Sciences and Engineering, The American University in Cairo, AUC Avenue, New Cairo 11835, Egypt; mfawzyaly@aucegypt.edu (M.F.A.); ihamdys@aucegypt.edu (I.H.A.) 1 Department of Mechanical Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; ajabbar@ksu.edu.sa (A.A.A.-A.); ianaser@ksu.edu.sa (I.A.A.) 4 Department of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Fouad 42526, Egypt; ahmed.elkaseer@kit.edu 5 Institute for Automation and Applied Informatics, Karlsruhe Institute of Technology, 76344 Karlsruhe, Germany
AuthorAffiliation_xml	– name: 1 Department of Mechanical Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia; ajabbar@ksu.edu.sa (A.A.A.-A.); ianaser@ksu.edu.sa (I.A.A.) – name: 4 Department of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Fouad 42526, Egypt; ahmed.elkaseer@kit.edu – name: 3 Department of Mechanical Engineering, Faculty of Engineering, Fayoum University, Fayoum 63514, Egypt – name: 2 Department of Mechanical Engineering, School of Sciences and Engineering, The American University in Cairo, AUC Avenue, New Cairo 11835, Egypt; mfawzyaly@aucegypt.edu (M.F.A.); ihamdys@aucegypt.edu (I.H.A.) – name: 5 Institute for Automation and Applied Informatics, Karlsruhe Institute of Technology, 76344 Karlsruhe, Germany
Author_xml	– sequence: 1 givenname: Adel T. orcidid: 0000-0002-2627-024X surname: Abbas fullname: Abbas, Adel T. – sequence: 2 givenname: Abdulhamid A. orcidid: 0000-0001-7672-4396 surname: Al-Abduljabbar fullname: Al-Abduljabbar, Abdulhamid A. – sequence: 3 givenname: Ibrahim A. orcidid: 0000-0001-6325-8410 surname: Alnaser fullname: Alnaser, Ibrahim A. – sequence: 4 givenname: Mohamed F. surname: Aly fullname: Aly, Mohamed F. – sequence: 5 givenname: Islam H. orcidid: 0000-0003-4698-1329 surname: Abdelgaliel fullname: Abdelgaliel, Islam H. – sequence: 6 givenname: Ahmed orcidid: 0000-0002-2500-3617 surname: Elkaseer fullname: Elkaseer, Ahmed
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Keywords	material removal rate multi-objective optimization AISI 4340 alloy steel wiper insert surface integrity surface quality
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Snippet	This article reports an extended investigation into the precision hard turning of AISI 4340 alloy steel when machined by two different types of inserts: wiper...
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SubjectTerms	Alloy steels Combustion chambers Cutting speed Feed rate Genetic algorithms Geometry Inserts Manufacturers Manufacturing Multiple objective analysis Nose Optimization techniques Pareto optimization Process parameters Productivity Researchers Robustness (mathematics) Search algorithms Steel alloys Surface properties Surface roughness Turning (machining)
Title	A Closer Look at Precision Hard Turning of AISI4340: Multi-Objective Optimization for Simultaneous Low Surface Roughness and High Productivity
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