Optimization of cutting conditions for minimum residual stress,cutting force and surface roughness in end milling of S50C medium carbon steel |
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| Affiliation: | 1. Universiti Kuala Lumpur, Institute of Product Design and Manufacturing, Cheras, 56100 Kuala Lumpur, Malaysia;2. Centre of Advanced Manufacturing and Material Processing, Department of Mechanical Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia;3. Department of Mechanical Engineering, Faculty of Engineering, Assiut University, 71516 Assiut, Egypt;1. National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;2. State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;1. Faculty of Mechanical Engineering and Management, Poznan University of Technology, 3 Piotrowo Street, 60-965 Poznan, Poland;2. Faculty of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana Street, 65-516 Zielona Gora, Poland;3. Turbocharger Research Institute, University of Huddersfield, Huddersfield HD1 3DH, UK;4. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758 Opole, Poland |
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| Abstract: | Residual stresses are usually imposed on a machined component due to thermal and mechanical loading. Tensile residual stresses are detrimental as it could shorten the fatigue life of the component; meanwhile, compressive residual stresses are beneficial as it could prolong the fatigue life. Thermal and mechanical loading significantly affect the behavior of residual stress. Therefore, this research focused on the effects of lubricant and milling mode during end milling of S50C medium carbon steel. Numerical factors, namely, spindle speed, feed rate and depth of cut and categorical factors, namely, lubrication and milling mode is optimized using D-optimal experimentation. Mathematical model is developed for the prediction of residual stress, cutting force and surface roughness based on response surface methodology (RSM). Results show that minimum residual stress and cutting force can be achieved during up milling, by adopting the MQL-SiO2 nanolubrication system. Meanwhile, during down milling minimum residual stress and cutting force can be achieved with flood cutting. Moreover, minimum surface roughness can be attained during flood cutting in both up and down milling. The response surface plots indicate that the effect of spindle speed and feed rate is less significant at low depth of cut but this effect significantly increases the residual stress, cutting force and surface roughness as the depth of cut increases. |
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| Keywords: | RSM Lubrication Milling Residual stress Cutting force Surface roughness |
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