In this study, a new model was proposed for the Product Sustainability Index (PSI). The PSI estimation was based on the tool life, the cutting force, the surface finish, the energy consumption, the operation cost and the acoustic emissions. The PSI of four mould steels (SF-2312 [300 HB], SF-5 [300 HB], SF-2000 [341 HB] and SP-300 [341 HB]) was evaluated using the developed model and machinability data from dry and wet cutting tests. The model was able to predict the PSI of the considered mould steels at different cutting speeds, and the predicted results were in good agreement with the experimental measurements. The PSI was found to be dependent on lubrication mode, cutting speed and workpiece hardness. Steels with similar composition but different hardness exhibits different PSI.
Ideally, the number of experiments carried out, either with the finite element model (FEM) or using other approaches, during the application of RSM, should be as small as possible, in order to reduce data-processing requirements.Properly selecting the points to be used for www.intechopen.comAn Approach-Based on Response Surfaces Method and Ant Colony System for Multi-Objective Optimization: A Case Study 53 the simulation will allow a reduction of the variance of the coefficients of the mathematical model, which will in turn ensure that the response surfaces obtained are more reliable.To that end, we need to determine the experimental design to be adopted in order to obtain the most interesting simulation for this problem.The central composite design (CCD) was employed in the case of the second-order response surface, but other types of plans, such as the complete factorial design and the fractional factorial design, are also available for use.Once the mathematical models are obtained, we need to verify that they produce an adequate approximation of the actual study system.The statistic selection criterion is the coefficient of determination R², which must be as close as possible to 1 (0
RésuméL’usinage à sec est une technologie prometteuse pour réduire les coûts ďusinage et éliminer les effets néfastes des lubrifiants sur l’environnement et sur la santé. Cette technologie est cependant difficile à appliquer pour des matériaux qui collent sur l’outil ou pour des composites qui usent rapidement les outils de coupe.Dans ce travail, l’influence des paramètres de coupe, des alliages et des particules dures (SiC, Al2O3) et douces (graphite) sur les forces de coupe et sur le mécanisme de formation des copeaux lors de l’usinage à sec est présentée. Les résultats obtenus montrent que les lois d’usinage reliant les forces aux conditions de coupe restent valides pour les composites testés et pour des vitesses jusqu’ à 150 m/min.AbstractDry machining is a very promising technology to reduce the machining cost and eliminate the negatives effects of lubricants on environment and on health. This technology is however difficult to apply for gummy materials which adhere to the cutting tools and for composites materials that wear out quickly the tools.In this research work, the effect of the cutting parameters, the alloys and that of hard particles (SiC, Al2O3) and soft particles (graphite) on the cutting forces and chip formation during dry machining is presented. The results obtained show that the machining laws relating the cutting conditions to the cutting force remain valid for the composites tested and for cutting speeds up to 150 m/min.
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