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MULTI-RESPONSE OPTIMIZATION OF X20Cr13 STEEL TURNING UNDER VORTEX

TUBE COOLING USING GREY RELATIONAL ANALYSIS

Tihana Kostadin, Goran Cukor, Zoran Jurković

T. Kostadin, Karlovac University of Applied Sciences, I. Meštrovića 10, 47000 Karlovac


Prof. G. Cukor, D.Sc, University of Rijeka, TF, Vukovarska 58, 51000 Rijeka
Assoc. Prof. Z. Jurković, D.Sc, University of Rijeka, TF, Vukovarska 58, 51000 Rijeka

Keywords: vortex tube cooled turning, martensitic cutting zone, by thermoelectric air cooler or by
stainless steel, grey relational analysis cryogenic compressed air cooler [2].
Surface roughness is a widely used index of
Abstract product quality. Also, a low surface roughness
This study presents multi-response optimization contributes to the corrosion resistance of product.
of X20Cr13 martensitic stainless steel turning At the same time, material removal rate is
under vortex tube cooling conditions. Turning recognized as the factor that directly affects the
experiments were carried out based on Taguchi L9 machining hour rate and costs. Since the surface
orthogonal array and the monitored machining roughness and material removal rate are in
responses, namely surface roughness and material correlation with the cutting parameters, the
removal rate were concurrently optimized based on optimum cutting parameters are a key factor in the
the grey relational analysis (GRA). In addition, production of high-quality parts in a short time and
statistical significance and percentage contribution with reduced costs.
of cutting parameters, i.e. cutting speed, feed and Certain statistical methods like Taguchi method
depth of cut were obtained by the analysis of (TM), grey relational analysis (GRA) and analysis
variance (ANOVA) and their optimal solution was of variance (ANOVA) can be implemented to
validated by a confirmation experiment. analyze and optimize the cutting parameters. TM
uses a special design of orthogonal arrays to study
1. INTRODUCTION the entire space of parameters with a small number
Martensitic stainless steels can be easily of experiments only. However, the original TM has
hardened by a two-stage heat-treatment process of been designed to optimize a single process
quenching and tempering. Hence, they can achieve response. GRA can convert simultaneous
superior strength and hardness levels in optimization of the multiple process responses into
comparison to ferritic and austhenitic stainless optimization of a single one called the grey
steels. Amongst other, application of martensitic relational grade [3]. The purpose of the ANOVA is
stainless steels includes steam, gas and jet turbine to determine the contribution of input parameters to
blades, valves and also extending to the surgical the output process response.
tools as well as aerospace components. Their high Few studies have been reported on the
degree of work hardening rate, low thermal determination of optimum cutting parameters for
conductivity and tendency to form long chips and turning martensitic stainless steels employing
built up edge designate them as difficult-to-cut ANOVA with TM and GRA or their combination.
materials. Thus, the use of cooling/lubrication is The studies have focused on AISI 410, AISI 416
necessary during the cutting operations [1]. and AISI 440B workpiece materials using
The growing challenge in industry is to perform TiCN/Al2O3, Ti(C, N, B), (Ti, Al)N, ceramics and
machining in a green environment but without PcBN cutting tools in wet or dry machining
sacrificing the machining performance. Traditional conditions. The machining responses considered
liquid cutting fluids in so-called wet machining for single or multi-optimization problem were:
create several health and environmental problems, surface roughness [4-9], tool wear [6, 8], machining
particularly about their degradation, and ultimate time [9] and material removal rate [5, 9]. The
disposal is a major difficulty. Therefore, many literature survey indicates that there is no study
companies have adopted chilled air-cooling as an dealing with the turning of the martensitic stainless
alternative cooling method, having varying degrees steel under chilled-air cooling.
of success in replacing traditional liquid cutting Herein, the vortex tube cooled turning of
fluids supplied by flooding. An environmentally martensitic stainless steel X20Cr13 (AISI 420) is
chilled air supply can be performed by vortex tube analysed and the concurrent optimization of
for cooling and jetting the compressed air to the multiple machining responses based on the grey

16th INTERNATIONAL SCIENTIFIC CONFERENCE ON PRODUCTION ENGINEERING –CIM2017


Croatian Association of Production Engineering, Zagreb 2017
CIM2017 June, 8-10, 2017 Zadar, Croatia

relational analysis combined with the Taguchi The material removal rate MRR was calculated
orthogonal array L9 for the design of experiments is using the following equation:
depicted. Statistical significance and percentage
contribution of the cutting parameters are obtained MRR  v c fap , (1)
by ANOVA. Finally, optimal solution for cutting
where vc is the cutting speed, f is the feed and ap is
parameters is verified in a confirmation experiment.
the depth of cut.
2. EXPERIMENTAL SETUP
2.2. Design of experiments
Significantly reducing the number of needed
2.1. Test material, machine tool, cutting tool
experiments, Taguchi orthogonal arrays are a
and measuring equipment
powerful tool for design of experiments (DOE). To
Test material was X20Cr13 martensitic stainless
perform the experiments, the levels of cutting
steel bar with dimensions Ø80 mm × 463 mm.
parameters were selected as listed in Table 3. The
Chemical composition and mechanical properties 3
experimental layout for Taguchi L9 (3 ) orthogonal
are given in Table 1 and Table 2 respectively, and
array is shown in Table 4.
martensitic structure is visible in Figure 1.
External turning was performed on the CNC
Table 3. Cutting parameters and their levels
lathe Prvomajska TU 360 with SECO tooling items:
Cutting Level
cutting inserts DNMG 150608-MF-4 TP 2501 and Simbol
PDJNR 2525M15 tool holder. Ranque-Hilsch parameter 1 2 3
TM
counter-flow vortex tube Nex Flow Frigid-X Cutting speed
A 170 220 270
Cooler System c/w 57025AD with an inlet air vc, m/min
pressure of 0,69 MPa was used for cooling and Feed
jetting the compressed air to the cutting zone. B 0,2 0,3 0,4
f, mm/rev.
The surface roughness parameter Ra (average
Depth of cut
roughness) was measured using the Hommel C
ap, mm
0,3 0,4 0,5
Tester T1000 device.
3
Table 1. Chemical composition of X20Cr13 steel Table 4. Experimental layout for Taguchi L9 (3 )
orthogonal array
Fe C Si Mn P S
% % % % % % Exp. A B C
# Cutting speed Feed Depth of cut
85,85 0,236 0,352 0,683 0,044 0,023
1 1 1 1
Cr Mo Ni V Nb Cu
% % % % % % 2 1 2 2

11,97 0,125 0,299 0,053 0,07 0,195 3 1 3 3


4 2 1 2
Table 2. Mechanical properties of X20Cr13 steel 5 2 2 3
Yield Tensile 6 2 3 1
Elongation Hardness
strength strength 7 3 1 3
% HB
MPa MPa
8 3 2 1
750 881 16,36 272
9 3 3 2

3. RESULTS AND DISCUSSION

3.1. Grey relational analysis for the


experimental results
First, the grey relational generation has to be
performed in order to normalize the experimental
results in the range between 0 and 1 due to
different measurement units. Thus, the normalized
experimental results for machining response Ra
according to smaller-the-better (S-T-B) criterion
can be expressed as:
max y ij  y ij
xij  , (2)
max y ij  miny ij

Figure 1. Microstructure of X20Cr13 steel where yij are original data (the i-th experimental
(500x magnification) result for the j-th machining response). The

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June, 8-10, 2017 Zadar, Croatia CIM2017

normalized experimental results for machining the ideal ones. Experiment #7 has the best
response MRR corresponding to larger-the-better combination of cutting parameters among 9
(L-T-B) criterion can be expressed as: performed experiments since it has the highest Γi
as depicted in Table 6 and Figure 2.
y ij  miny ij
xij  . (3) Mean grey relational grades calculated from
max y ij  miny ij Table 6 by taking average of the grey relational
grades for each level of input cutting parameters
Next, the grey relational coefficients (GRC) can individually are listed in Table 7. In addition, the
be calculated as: total mean of grey relational grades for 9
ζ experiments is also listed. Figure 3 shows the main
ξ ij  , (4) effects plot for the mean grey relational grades.
1  xij  ζ
The optimal combination of cutting parameters
where ζ  [0, 1] is the distinguishing coefficient,
which generally has a value of 0,5. ξij determines Table 5. Experimental results
how close the actual normalized experimental Surface Material
Exp.
results xij are to the reference or the ideal target roughness removal rate
# 3
sequence x0j = 1, and the larger the value of ξij, the Ra, μm MRR, mm /min
closer these two variables are. Moreover, the 1 1,281 10200
distinguishing coefficient ζ serves the purpose of 2 1,560 20400
expanding and compressing the range of ξij. It is
3 1,931 34000
important to note that regardless of the choice of ζ,
the ranking order of ξij remains the same [10]. 4 1,381 17600
The overall evaluation of n multiple machining 5 1,671 33000
responses is based on the grey relational grade 6 1,994 26400
(GRG), that is: 7 1,291 27000
n 8 2,371 24300
1
Γi   ξ ij .
n j 1
(5)
9 1,880 43200

If the effects of all machining responses are not


0,8
Grey relational grade

exactly the same, Equation (5) can be modified as


follows: 0,7
0,6
n n
0,5
Γ i   w j ξ ij , w j  1 , (6)
0,4
j 1 j 1
0,3
where wj represents the weight of j-th response. 0,2
Given the same weights, Equations (5) and (6) are 0,1
equal. 0
Table 5 shows the experimental results and 0 1 2 3 4 5 6 7 8 9
Table 6 shows the calculated Γi according to Experiment number
Equation (5). The higher Γi represents that the
corresponding machining responses are closer to Figure 2. Graph of grey relational grades

Table 6. Calculated grey relational grades


Normalized value of response Grey relational
Grey relational coefficient
Exp. Ideal sequence (1, 1) grade
# Ra MRR
Ra MRR Γi Rank
S-T-B L-T-B
1 1,000000 0,000000 1,000000 0,333333 0,666667 3
2 0,744037 0,309091 0,661408 0,419847 0,540628 7
3 0,403670 0,721212 0,456067 0,642023 0,549045 6
4 0,908257 0,224242 0,844961 0,391924 0,618443 4
5 0,642202 0,690909 0,582888 0,617978 0,600433 5
6 0,345872 0,490909 0,433227 0,495495 0,464361 8
7 0,990826 0,509091 0,981982 0,504587 0,743285 1
8 0,000000 0,427273 0,333333 0,466102 0,399718 9
9 0,450459 1,000000 0,476399 1,000000 0,738199 2

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CIM2017 June, 8-10, 2017 Zadar, Croatia

levels can easily be obtained from Table 7 or improving MRR, and is followed by depth of cut
Figure 3 by selecting the level of each cutting and cutting speed. However, the exact contribution
parameter with the highest mean grey relational steel needs to be found.
grade. Hence, the optimal combination is A3B1C2,
i.e. vc at level 3, f at level 1 and ap at level 2. 3.2. Analysis of variance (ANOVA)
According to the results presented in Table 7, The purpose of ANOVA is to identify the cutting
the feed has the largest effect in reducing Ra and parameters that significantly affect the grey
relational grade (GRG). Also, it can be used to
Table 7. Response table (means) for grey determine the contribution of the cutting parameter
relational grade change to the machining response. The degrees of
Cutting parameter freedom DF, sum of squares SS, mean squares
Level MS (variance) and F-value (variance ratio) were
A: vc B: f C: ap
calculated along with the percentage contribution
1 0,585446 0,676131 0,510249
PC of each parameter, and the results are
2 0,561079 0,513593 0,632423 presented in Table 8. PC indicates the relative
3 0,627067 0,583869 0,630921 power of a parameter to reduce variation. The
Max-Min 0,065988 0,162538 0,122174 higher the PC value, the more important is the
contribution of cutting parameter change. PC
Rank 3 1 2
values are shown separately in Figure 4. It can be
Total mean of grey relational grades = 0,591197 seen that feed influences the most (36,8 %) on the
martensitic stainless steel X20Cr13 turning
0,7
operation under vortex tube cooling when the
reducing of Ra and improving of MRR is
0,65
Means of GRG

concurrently considered followed by depth of cut


0,6 (27,2 %) and cutting speed (6,2 %). ANOVA also
0,55 shows that the contribution of error is very high
(29,8 %), which distinctly suggests the existence of
0,5
the interaction effects of cutting parameters.
0,45
0,4 Table 8. ANOVA results
0 1 2 3 Symbol DF SS MS F PC, %
Cutting speed level A 2 0,00668 0,00334 0,21* 6,2
B 2 0,03987 0,01994 1,23* 36,8
C 2 0,02949 0,01475 0,91* 27,2
0,7
Error 2 0,03231 0,01615 29,8
0,65
Means of GRG

Total 8 0,10835 100


0,6
F0-tabulated for α = 0,05: F0 = F(2, 2) = 19
0,55 *not significant
0,5
0,45
Cutting speed
0,4 6,2 %
0 1 2 3
Error
Feed level 29,8 %

0,7
Feed
0,65
Means of GRG

36,6 %
0,6
0,55
0,5
0,45
0,4 Depth
0 1 2 3 of cut
Depth of cut level 27,2 %

Figure 3. Main effects plot for the mean grey Figure 4. Percentage contributions of cutting
relational grades parameters

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Another interesting finding in Table 8 is that the Ra 1,381


cutting speed, feed and depth of cut had no
statistically significance on the GRG values at the
confidence level of 95% because the F-calculated
values are all less than F0-tabulated value. Hence, 1,284
a larger set of observations is needed, and an
option is the central composite design of
experiments (CCD).

3.3. Confirmation experiment


Once the optimal solution for cutting parameters MRR 21600
is identified, the final step is to predict and verify 17600
the improvements in the multiple machining
responses. The estimated grey relational grade can
be calculated as:

 
p
Γˆ opt  Γ t   Γ k  Γ t , (7)
k 1
where Γt is the total mean of grey relational grades,
Γk is the highest mean grey relational grade for the
cutting parameter in Table 7 and p is the number of Γi 0, 713798
cutting parameters that significantly affect the
multiple machining responses.
Table 9 shows the comparison of multiple
0,618443
machining responses for initial and optimal cutting
parameters. The initial designated levels of cutting
parameters are A2B1C2, which is the fourth
3
experiment in the L9 (3 ) experimental design.
According to grey relational analysis, the A3B1C2 Figure 5. Enhancements in machining
optimal solution is regarded as confirmation responses
experiment. As noted from Table 9, the surface
roughness Ra is improved from 1,381 μm to 1,284 experiments is very suitable for practical use in a
μm and the material removal rate MRR is machine shop.
3
accelerated from 17600 mm /min to 21600 It would be of further interest to compare both
3
mm /min. The grey relational grade is increased vortex tube cooling and conventional flood cooling
from 0,618443 to 0,713798. These enhancements considering the corrosion resistance of the tested
are graphically presented in Figure 5. material. For this purpose, it is suggested to
establish a mathematical model between the
4. CONCLUSION corrosion resistance and the surface roughness
The optimization of cutting parameters with considering aforementioned cooling techniques.
multiple machining responses (low Ra, high MRR) The central composite design of experiments
for the vortex tube cooled turning of martensitic (CCD) has to be used since both the nonlinear
stainless steel X20Cr13 was carried out. The model and the influence of interactions among
optimum cutting parameters were: vc = 270 m/min, cutting parameters are anticipated. The impact of
f = 0,2 mm/rev. and ap = 0,4 mm. ANOVA shows cooling techniques on the tool life must be
that the feed is the dominant cutting parameter examined too.
contributing the most to the concurrent reducing of
Ra and improving of MRR. Regarding the multi- 5. ACKNOWLEDGEMENT
response optimization problem, it should be noted This work was financially supported by the
that the grey relational analysis (GRA) combined University of Rijeka, Croatia, contract number
with Taguchi orthogonal array for the design of 13.09.1.2.10.

Table 9. Results of confirmation experiment


Initial cutting Optimal cutting parameters
parameters Prediction Experiment
Setting level A2B1C2 A3B1C2 A3B1C2
Surface roughness Ra, μm 1,381 1,284
3
Material removal rate MRR, mm /min 17600 21600
Grey relational grade Γi 0,618443 0,753227 0,713798
Improvement of the grey relational grade = 0,095355

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[1] BSSA, 2017, General principles of machining pp. 1-4.
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topics.php?article=192. Hard Turning of Martensitic Stainless Steel
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[6] Ahamed Meeran, R., Chandrasekaran, K.,
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