Surface roughness evaluation of ferrous alloys by using predictive model

Other Title(s)

تقييم خشونة السطوح لسبائك حديدية مشغلة بالخراطة باستخدام نموذج استنباطي إحصائي

Dissertant

Abu Mandil, Rafat Salim Abd Allah

Thesis advisor

al-Tai, Abbas Jawad
Abu Saa, Fathi

University

Omdurman Islamic University

Faculty

Faculty of Engineering

Department

Department of Mechanical Engineering

University Country

Sudan

Degree

Master

Degree Date

2008

English Abstract

There are different machining parameters have effects on surface roughness, but those effects have not been quantified.

several researches studied the effects of different combinations of machining parameters on surface roughness to achieve an accurate predictive models for surface roughness, and still more researches has to be conducted, hence, this research was carried out.

spare parts for textile machines need to be manufactured with high surface finish and close tolerances to reduce friction heat and vibration.

To manufacture these parts, four types of steel available locally has been chosen, to reduce maintenance cost by substituting imported parts.

Four different types of steels were used (AISI C1040 carbon steel, PH14-8MO nickel-chromium alloy steel AISI C1020 carbon steel, and 5-35-NCI gray cast iron) with HRB hardness 115,101,95, and 90 respectively.

Material bars were machined by turning, using high precision URPE lathe model 4-M.

Emulsion oil RP–0040596 was used as a coolant and Cemented carbide insert tool was used through the work.

Three parameters (cutting speed, feed rate, and depth of cut) were used independently and statistical analysis of variances was performed and roughness of machined samples were measured.

It has been shown that AISI C1040 carbon steel gave the best correlation with surface roughness all over the experiments.

Lower feed rate and lower depth of cut resulted in better surface roughness.

In a certain range of cutting speed variation the lower cutting speed resulted in better surface roughness due to forming of built-up edge.

This result contradicts the known trend of roughness, So, a second round of experiments were executed, utilizing Taguchi experimental design to determine the optimal machining parameters for a desired surface roughness, and to identify the impact of various parameters on an output and to determine the combination of parameters to reduce the variability in that output.

CNC lathe model LTC – 20B has been utilized in second round of experiments and statistical software program, SPSS version 12, was employed in regression prediction model, and two prediction equations for roughness simulation has been obtained.

Main Subjects

Mechanical Engineering

Topics

• Mechanical properties
• Friction
• Steel alloys

No. of Pages

74

Table of Contents

• APA
• MLA
• AMA

Language

English

Data Type

Arab Theses

Record ID

BIM-363040