Analysis and Optimization of Machining Hardened Steel AISI 4140 with Self-Propelled Rotary Tools
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- @Article{ahmed:2021:Materials,
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author = "Waleed Ahmed and Hussien Hegab and Atef Mohany and
Hossam Kishawy",
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title = "Analysis and Optimization of Machining Hardened Steel
{AISI} 4140 with {Self-Propelled} Rotary Tools",
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journal = "Materials",
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year = "2021",
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volume = "14",
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number = "20",
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keywords = "genetic algorithms, genetic programming, modeling,
machining, optimization, rotary tools",
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ISSN = "1996-1944",
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URL = "https://www.mdpi.com/1996-1944/14/20/6106",
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DOI = "doi:10.3390/ma14206106",
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abstract = "It is necessary to improve the machinability of
difficult-to-cut materials such as hardened steel,
nickel-based alloys, and titanium alloys as these
materials offer superior properties such as chemical
stability, corrosion resistance, and high strength to
weight ratio, making them indispensable for many
applications. Machining with self-propelled rotary
tools (SPRT) is considered one of the promising
techniques used to provide proper tool life even under
dry conditions. In this work, an attempt has been
performed to analyse, model, and optimise the machining
process of AISI 4140 hardened steel using
self-propelled rotary tools. Experimental analysis has
been offered to (a) compare the fixed and rotary tools
performance and (b) study the effect of the inclination
angle on the surface quality and tool wear. Moreover,
the current study implemented some artificial
intelligence-based approaches (i.e., genetic
programming and NSGA-II) to model and optimise the
machining process of AISI 4140 hardened steel with
self-propelled rotary tools. The feed rate, cutting
velocity, and inclination angle were the selected
design variables, while the tool wear, surface
roughness, and material removal rate (MRR) were the
studied outputs. The optimal surface roughness was
obtained at a cutting speed of 240 m/min, an
inclination angle of 20?, and a feed rate of 0.1
mm/rev. In addition, the minimum flank tool wear was
observed at a cutting speed of 70 m/min, an inclination
angle of 10?, and a feed rate of 0.15 mm/rev. Moreover,
different weights have been assigned for the three
studied outputs to offer different optimised solutions
based on the designer's interest (equal-weighted,
finishing, and productivity scenarios). It should be
stated that the findings of the current work offer
valuable recommendations to select the optimised
cutting conditions when machining hardened steel AISI
4140 within the selected ranges.",
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notes = "also known as \cite{ma14206106}",
- }
Genetic Programming entries for
Waleed Ahmed
Hussien Hegab
Atef Mohany
Hossam A Kishawy
Citations