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Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

Nguyen, Trung-Thanh and Le, Chi-Hieu ORCID: 0000-0002-5168-2297 (2020) Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness. Journal of Engineering Manufacture: Proceedings of the Institution of Mechanical Engineers, Part B., 235 (6-7). pp. 1179-1196. ISSN 0954-4054 (Print), 2041-2975 (Online) (doi:https://doi.org/10.1177/0954405420976661)

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Abstract

The burnishing process is used to enhance the machining quality via improving the surface finish, surface hardness, wear-resistance, fatigue, and corrosion resistance, and it is mostly used in aerospace, biomedical, and automotive industries to improve reliability and performance of the component. The combined turning and burnishing process is therefore considered as an effective solution to enhance both machining quality and productivity. However, the trade-off analysis between energy consumption, surface characteristics, and production costs has not been well-addressed and investigated. This study presents an optimization of the compressed air assisted-turning-burnishing (CATB) process for aluminum alloy 6061, aimed to decrease the energy consumption as well as surface roughness and to enhance the Vicker hardness of the machined surface. The machining parameters for consideration include the machining speed, feed rate, depth of cut, burnishing force, and the ball diameter. The improved Kriging models were used to construct the relations between machining parameters and the technological response characteristics of the machined surface. The optimal machining parameters were obtained utilizing the desirability approach. The energy based-cost model was developed to assess the effectiveness of the proposed CATB process. The findings showed that the selected optimal outcomes of the depth of cut, burnishing force, diameter, feed rate, and machining speed are 0.66 mm, 196.3 N, 8.0 mm, 0.112 mm/rev, and 110.0 m/min, respectively. The energy consumption and surface roughness are decreased by 20.15% and 65.38%, respectively, while the surface hardness is improved by 30.05%. The production cost is decreased by 17.19% at the optimal solution. Finally, the proposed CATB process shows a great potential to replace the traditional techniques which are used to machine non-ferrous metals.

Item Type: Article
Additional Information: This journal paper is the outcome of the international collaborations, and the results of the following funded projects: (1) Network of Excellence and Hi-Tech Hub for Vietnam's Industry 4.0 via the UK-VN collaborations in Smart Manufacturing [Acronym: i4SMART]. Funded by Newton Fund – Research Environment Links Programme (1/2020-01/2021). Budget: £108,545 GBP. Grant ID No.: 528085858. (2) Transnational Education and Research via the Academic Mobility, Business-University Collaborations and the Joint Postgraduate Programmes in Sustainability, Innovation and Entrepreneurship. Funded by British Council – Higher Education Partnership Fund, UK-VN-HEP (10/2018-06/2021). Budget: 60,000 GBP. Grant ID No.: UK-VN-HEP 2018-2019.
Uncontrolled Keywords: turning, burnishing, energy, roughness, hardness, optimisation, kriging, desirability
Subjects: T Technology > TA Engineering (General). Civil engineering (General)
Faculty / Department / Research Group: Faculty of Engineering & Science
Faculty of Engineering & Science > Design, Manufacturing and Innovative Products Research Theme
Faculty of Engineering & Science > School of Engineering (ENN)
Last Modified: 27 Jul 2021 08:54
Selected for GREAT 2016: None
Selected for GREAT 2017: None
Selected for GREAT 2018: None
Selected for GREAT 2019: None
Selected for REF2021: None
URI: http://gala.gre.ac.uk/id/eprint/30443

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