Strain rate analyses during elliptical vibration cutting of Inconel 718 using finite element analysis, Taguchi method, a
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Strain rate analyses during elliptical vibration cutting of Inconel 718 using finite element analysis, Taguchi method, and ANOVA Hai-Bo Xie1 • Zi-Qing Yang1 • Na Qin1
•
Zhan-Jiang Wang1
Received: 3 February 2020 / Revised: 10 May 2020 / Accepted: 12 June 2020 Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract The high strain rate in metal cutting significantly affects the mechanical properties of the work piece by altering its properties. This study outlines the material strain rates during elliptical vibration cutting. The finite element analysis, Taguchi method, and analysis of variance (ANOVA) were employed to analyze the effects and contributions of cutting and vibration process parameters (feed rate, rake angle, tangential amplitude, and frequency of vibration) on the variation of strain rates during machining of Inconel 718. Taguchi signal-to-noise analysis on an L18 (21 9 33) orthogonal array was used to determine the optimum parametric combination for the maximum strain rate, and ANOVA was applied to evaluate the significance of control parameter factors on the strain rate. The results of the finite element analysis under different conditions illustrated that the feed rate and rake angle were negatively related to the strain rate, whereas the tangential amplitude and frequency had a positive response. Furthermore, ANOVA results indicated that the effect of the feed rate, tool rake angle, vibration frequency, and tangential amplitude on the strain rate were all statistically significant, with a reliability level of 95%. Of these, the dominant parameter affecting the strain rate was the feed rate, with a percentage contribution of 40.36%. The estimation of the optimum strain rate and confirmation tests proved that the Taguchi method could successfully optimize the working conditions to obtain the desired maximum strain rate.
& Na Qin [email protected] 1
Tribology Research Institute, Department of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, People’s Republic of China
Keywords Elliptical vibration cutting Strain rate Finite element (FE) Taguchi method Analysis of variance (ANOVA)
1 Introduction Metal cutting is a process in which materials are severely deformed under a high strain rate and temperature in extremely intense conditions. The strain rates localized in the deformation zone during high speed machining are in the order of 103–106 s-1 [1, 2]. It is believed that the high strain rate occurring during metal cutting significantly changes the mechanical properties of the workpiece during processing, including grain refinement [3–6], temperature rise, and nano-twinning [7]. Therefore, analyses of the strain rate during metal cutting are critical for improving the cutting accuracy of the materials. Several efforts have been made by researchers to study the strain rates encountered in metal cutting by using different methods. Based on the experimental results, researchers [8–11] used analytical models to estimate t
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