MULTI-OBJECTIVE OPTIMIZATION OF CUTTING PARAMETERS FOR CNC TURNING 42CRMO4 HARDENED STEEL USING UTILITY FUNCTION
DOI:
https://doi.org/10.17770/etr2025vol4.8413Keywords:
multi-objective optimization, generalized utility function, CNC turning, 42CrMo4 hardened steelAbstract
The optimum turning conditions for 42CrMo4 hardened steel, defined and recommended in the literature, are valid only for certain cutting tools and machine tools. In this paper, an attempt has been made to optimize the cutting parameters for CNC turning with robotic power supply of the machine tool by using a new type of CVD coated replaceable carbide insert as cutting tool. To determine the optimal cutting conditions such as cutting speed, feed and depth of cut, a multi-objective optimization, based on a genetic algorithm, was conducted. The generalized arithmetic mean utility function with weighting coefficients has been chosen as the optimization parameter, which is a complex index characterizing the cutting tool lifetime and production rate in turning. The optimization problem has been solved in the following sequence: 1) a model of the generalized utility function was created, reflecting the complex influence of the turning process parameters; 2) the optimal cutting conditions were determined, under which the generalized utility function has a maximum; 3) Pareto optimal solutions were found, which guarantee the best combination between tool lifetime and production rate in turning.
References
L Mukherjee and P. K. Ray, "A review of optimization techniques in metal cutting processes." Computers&Industrial Engineering, vol. 50(1-2), pp. 15-34, 2006, https:// doi.org/10.1016/j.cie.2005. 10.001
X. Wang, Z. J. Da, A. K. Balaji ,and I. S. Jawahir, "Performance-Based Predictive Models and Optimization Methods for Turning Operations and Applications: Part 3 - Optimum Cutting Conditions and Selection of Cutting Tools." Journal of Manufacturing Processes, vol. 9(1), pp. 61-74, 2007, https://doi.org/10.1016/S1526-6125(07)70108-1.
E. Aslan, N. Camuscu, and B. Bingoren, "Design optimization of cutting parameters when turning hardened AISI 4140 (63 HRC) with Al2O3 + TiCN mixed ceramic tool." Materials & Design, vol. 28, pp. 1618-1622, 2007, https://doi:10.1016/j.matdes.2006.02.006.
H. Akkuş, "Experimental and Statistical Investigation of Ra in Turning of AISI 4140." Sakarya University Journal of Science, vol. 23(5), pp. 775-781, 2019, https://doi.org/10.16984/saufenbilder.490668.
S. R. Das, D. Dhupal, and A. Kumar, "Study of surface roughness and flank wear in hard turning of AISI 4140 steel with coated ceramic inserts." J Mech Sci Technol, vol. 29, pp. 4329–4340, 2015, https://doi.org/10.1007/s12206-015-0931-2.
A.R Motorcu, Y. Isik, A. Kus, and M.C. Cakir, "Analysis of the cutting temperature and surface roughness during the orthogonal machining of AISI 4140 alloy steel via the taguchi method." Materiali in Tehnologije, vol. 50(3), pp. 343-351, 2016.
G. Sharan and R. K. Patel, "Optimization of cutting parameters of turning for hardness of AISI 4140 alloy steel." in ICMPC-2019, Materials Today: Proceedings, vol. 18, pp. 3582–3589, 2019.
B. Hamadi, M.A. Yallese, L. Boulanouar, A Hammoudi, and M. Nouioua. "Evaluation of the cutting performance of PVD, CVD and MTCVD carbide inserts in dry turning of AISI 4140 steel using RSM-based NAMDE optimization." J Braz. Soc. Mech. Sci. Eng. vol. 44, pp. 342+, 2022. https://doi.org/10.1007/s40430-022-03633-5.
Padhan, N.K.Wagri. L. Dash, A. Das, S.R. Das, M. Rafighi, and P. Sharma, "Investigation on Surface Integrity in Hard Turning of AISI 4140 Steel with SPPP-AlTiSiN Coated Carbide Insert under Nano-MQL." Lubricants, vol. 49(11), 2023, https://doi.org/10.3390/lubricants11020049.
I. Meddour, M.A. Yallese, H. Bensouilah, A. Khellaf and M. Elbah, "Prediction of surface roughness and cutting forces using RSM, ANN, and NSGA-II in finish turning of AISI 4140 hardened steel with mixed ceramic tool." Int J Adv Manuf Technol, vol. 97, pp. 1931–1949, (2018), https://doi.org/10.1007/s00170-018-2026-6.
V. S. Konnur, S. S. Kulkarni, S. V. Hiremath, V.S. Kanal, and V.C Nirale, "Analysis of CNC turning parameters and simultaneous optimisation of surface roughness and material removal rate by MOGA for AISI 4340 alloy steel." Advances in Materials and Processing Technologies, 12 Nov 2023, https://doi.org/10.1080/2374068X.2023.2280293.
O. Manav, S. Chinchanikar, and M. Gadge, "Multi-performance optimization in hard turning of AISI 4340 Steel using Swarm Optimization technique", in IConAMMA_2017, Materials Today: Proceedings, vol. 5, pp. 24652–24663, 2018.
R. Q. Sardiñas, M. R. Santana, and E. A. Brindis, "Genetic algorithm-based multi-objective optimization of cutting parameters in turning processes." Particle Engineering Applications of Artificial Intelligence, vol. 19(2), pp. 127-133, 2006, https://doi.org/10.1016/j.engappai.2005.06.007.
S. Chinchanikar and S. K. Choudhury, "Effect of work material hardness and cutting parameters on performance of coated carbide tool when turning hardened steel: An optimization approach." Measurement, vol. 46, pp. 1572-1584, 2013, https://doi.org/10.1016/j.measurement. 2012.11.032.
A. Aleksandrov and I. Aleksandrova, Theory of Experiment, Gabrovo, Bulgaria: Experess, 2012.
S. Kumari, D. Bandhu, A. Kumar, R. K. Yadav, K. Vivekananda, "Application of Utility Function Approach Aggregated with Imperialist Competitive Algorithm for Optimization of Turning Parameters of AISI D2 Steel.“ in Lecture Notes in Intelligent Transportation and Infrastructure, Recent Advances in Mechanical Infrastructure, A. Parwani, P. Ramkumar, Eds. Singapore: Springer, 2020, https://doi.org/10.1007/978-981-32-9971-9_6.
"Overview of 42CrMo4 Steel: Properties and Applications.” [Online]. Available: https://ambhe.com/42crmo4-steel/. [Accessed: Feb. 16, 2025].
"ISCAR Cutting Tools - Metal Working Tools.” [Online]. Available: https://www.iscar.bg/index.aspx/countryid/38/lang/bg. [Accessed: Feb. 16, 2025].
I. N. Vuchkov and I. I. Vuchkov, Statistical methods of quality control, robust engineering, planning, modeling and optimization, QStatLab, v 5.3, 2009.
Downloads
Published
Issue
Section
License
Copyright (c) 2025 Hristo Metev, Irina Aleksandrova, Nikolay Kolev
This work is licensed under a Creative Commons Attribution 4.0 International License.