Browsing by Author "Prajwala, B.K."

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Cutting Forces, Surface Roughness and Tool Wear Quality Assessment Using ANN and PSO Approach During Machining of MDN431 with TiN/AlN-Coated Cutting Tool
(Springer Verlag, 2019) V Badiger, P.V.; Desai, V.; Ramesh, M.R.; Prajwala, B.K.; Raveendra, K.
The aim of this study was to improve the life and performance of tungsten carbide turning tool inserts coated with TiN/AlN multilayer thin films using physical vapor deposition technique. Quality characteristics of the coating are evaluated using Calo and VDI 3198 tests. Thickness of the coating is found to be 3.651?m with adhesion quality of HF1. The performance of coated tool inserts is evaluated using cutting speed (59–118 m/min), feed rate (0.062–0.125 mm/rev) and depth of cut (0.2–0.4 mm) as process parameters in turning MDN431 steel. Experimental investigation has been carried out based on full factorial design, and regression analysis was used to analyze and build the mathematical models for cutting force and surface roughness. Multi-objective optimization of the process parameters has been done with the combination of desirability approach and MOPSO technique. Optimum machining condition for least cutting force and optimum surface roughness is found to be Vc=59m/min, f=0.063mm/rev and ap=0.2mm. Cutting force and surface roughness are reduced by 9% in TiN/AlN-coated tools compared with the uncoated tool. To improve the CoD and capability of predictive regression models, ANN modeling has been adopted. ANN trained model and mathematical regression models are used to predict the results and predict the responses, which follow the experimental data with minimum absolute error. The predicted results are validated using ANN and regression analysis found with minimum error, and developed models are adequate for further usage. Tool wear was reduced by 105% in TiN/AlN-coated tools compared with the uncoated tool. © 2019, King Fahd University of Petroleum & Minerals.
Effect of cutting parameters on tool wear, cutting force and surface roughness in machining of MDN431 alloy using Al and Fe coated tools
(Institute of Physics Publishing helen.craven@iop.org, 2019) V Badiger, P.V.; Desai, V.; Ramesh, M.R.; Prajwala, B.K.; Raveendra, K.
Thin solid films are used in cutting tools in order to improve its performance, reduce tool wear and improve tool life. Cathodic arc evaporation is the state of art PVD technique widely accepted in industries for the development of thin solid films. The turning cutting tool inserts are coated with AlCN/AlC and FeCrN monolayer thin solid films using cathodic arc evaporation technique. Quality characteristics of thin films are estimated using Calo and VDI3198 tests. Thickness of the coatings are found to be 1.430 and 1.475 ?m for AlCN/AlC and FeCrN coatings respectively and adhesion quality of HF1 is attained. Performance of the thin solid films are evaluated in machining MDN431 steel with range of cutting speed (59-118 m min-1), feed rate (0.062-0.125 mm/rev) and depth of cut (0.2-0.4 mm). Experiments are performed based on full factorial design and regression analysis. Optimization of the process parameters is carried out using combined techniques of desirability and Particle swarm optimisation (PSO). The objective of the study is to establish correlation between machining parameters with cutting force, tool wear and surface roughness. Optimal process parameter for least cutting force and surface roughness are obtained for coatings. ANN has been adopted to improve the coefficient of determination (CoD) and capability of predictive regression models. ANN trained model and mathematical regression models are adequate to predicted the responses, which follows the experimental data with minimum absolute error. The AlCN/AlC coatings exhibited lower cutting forces and surface roughness than FeCrN coated tools. Tool wear was reduced by 3.62 times in AlCN/AlC and 1.63 times in FeCrN coated tools compared to uncoated tool which is due to increased hardness and elastic modulus of the coating. © 2018 IOP Publishing Ltd.
Influence of Ti coated tools on process parameters in turning process of MDN431
(2020) Badiger, P.V.; Desai, V.; Ramesh, M.R.; Vinyas, M.; Santhosh, C.M.; Prajwala, B.K.; Raveendra, L.
Tungsten carbide tool places in are coated by customized composition of Ti/TiCN/TiN/TiCN/TiN for multilayer and monolayer TiC-C using PVD assisted CAE technique. Quality physiognomies of coatings are evaluated using VDI3198 and Calo tests. Thickness of the coatings for Ti-multilayer and monolayer are found to be 1.837 and 1.198 ?m respectively and adhesion quality of HF1 attained. Highly alloyed steel MDN431 is used as machining material to evaluate the performance of coatings. The coated tool insert performance has been evaluated at the machining parameters cutting speed in the range of 59-118 m/min, feed rate is 0.062-0.125 mm/rev and depth of cut is ap 0.2-0.4 mm during machining of MDN431 steel. Experiments are conducted based on L27 full factorial design. Cutting forces and surface roughness are analysed using regression analysis. Desirability approach as well as PSO technique is used to optimize the process parameters. Least cutting force and surface roughness are obtained at the condition of Vc-118 m/min, f-0.063 mm/rev, ap-0.2 mm and Vc-59 m/min, f-0.63 mm/rev, ap - 0.2 mm for Ti-multilayer and TiC-C coatings respectively. To augment the capability of predictive regression models and coefficients of determination (COD), ANN modelling has been adopted. Cutting forces and surface roughness are predicted using ANN and mathematical regression models, predicted data follows the experimental data with minimum absolute error. Tool wear was reduced by 65.7% in Ti-multilayer and TiC-C coated tools compared to uncoated tool. � 2020 Author(s).
Influence of Ti coated tools on process parameters in turning process of MDN431
(American Institute of Physics Inc. subs@aip.org, 2020) V Badiger, P.V.; Desai, V.; Ramesh, M.R.; Mahesh, M.; Santhosh, C.M.; Prajwala, B.K.; Raveendra, L.
Tungsten carbide tool places in are coated by customized composition of Ti/TiCN/TiN/TiCN/TiN for multilayer and monolayer TiC-C using PVD assisted CAE technique. Quality physiognomies of coatings are evaluated using VDI3198 and Calo tests. Thickness of the coatings for Ti-multilayer and monolayer are found to be 1.837 and 1.198 Î¼m respectively and adhesion quality of HF1 attained. Highly alloyed steel MDN431 is used as machining material to evaluate the performance of coatings. The coated tool insert performance has been evaluated at the machining parameters cutting speed in the range of 59-118 m/min, feed rate is 0.062-0.125 mm/rev and depth of cut is ap 0.2-0.4 mm during machining of MDN431 steel. Experiments are conducted based on L27 full factorial design. Cutting forces and surface roughness are analysed using regression analysis. Desirability approach as well as PSO technique is used to optimize the process parameters. Least cutting force and surface roughness are obtained at the condition of Vc-118 m/min, f-0.063 mm/rev, ap-0.2 mm and Vc-59 m/min, f-0.63 mm/rev, ap - 0.2 mm for Ti-multilayer and TiC-C coatings respectively. To augment the capability of predictive regression models and coefficients of determination (COD), ANN modelling has been adopted. Cutting forces and surface roughness are predicted using ANN and mathematical regression models, predicted data follows the experimental data with minimum absolute error. Tool wear was reduced by 65.7% in Ti-multilayer and TiC-C coated tools compared to uncoated tool. Â© 2020 Author(s).