Multi-objective optimization of oblique turning operations using finite element model and genetic algorithm

Abstract

Multi-objective optimization of oblique turning operations while machining AISI H13 tool steel has been carried out using developed finite element (FE) model and multi-objective genetic algorithm (MOGA-II). The turning operation is optimized in terms of cutting force and temperature with constraints on required material removal rate and cutting power. The developed FE model is capable to simulate cutting forces, temperature and stress distributions, and chip morphology. The tool is modeled as a rigid body, whereas the workpiece is considered as elastic–thermoplastic with strain rate sensitivity and thermal softening effect. The effects of cutting speed, feed rate, rake angle, and inclination angle are modeled and compared with experimental findings. FE model is run with different parameters with central composite design used to develop a response surface model (RSM). The developed RSM is used as a solver for the MOGA-II. The optimal processing parameters are validated using FE model and experiments.

This is a preview of subscription content, access via your institution.

References

  1. 1.

    Moufki A, Devillez A, Dudzinski D, Molinari A (2004) Thermomechanical modelling of oblique cutting and experimental validation. Int J Mach Tools Manuf 44:971

    Article  Google Scholar 

  2. 2.

    Fang G, Zeng P (2005) Three-dimensional thermo–elastic–plastic coupled FEM simulations for metal oblique cutting processes. J Mater Process Technol 168:42

    Article  Google Scholar 

  3. 3.

    Zou GP, Yellowley I, Seethaler RJ (2009) A new approach to the modeling of oblique cutting processes. Int J Mach Tools Manuf 49:701

    Article  Google Scholar 

  4. 4.

    Adibi-Sedeh AH, Madhavan V, Bahr B (2003) Upper bound analysis of oblique cutting: improved method of calculating the friction area. Int J Mach Tools Manuf 43:485

    Article  Google Scholar 

  5. 5.

    Lazoglu I, Islam C (2012) Modeling of 3D temperature fields for oblique machining. CIRP Ann Manuf Technol 61:127

    Article  Google Scholar 

  6. 6.

    Li R, Shih AJ (2006) Finite element modeling of 3D turning of titanium. Int J Adv Manuf Technol 29:253

    Article  Google Scholar 

  7. 7.

    Llanos I, Villar JA, Urresti I, Arrazola PJ (2009) Finite element modeling of oblique machining using an arbitrary Lagrangian–Eulerian formulation. Mach Sci Technol 13:385

    Article  Google Scholar 

  8. 8.

    Ng E-G, Aspinwall DK (2002) Modelling of hard part machining. J Mater Process Technol 127:222

    Article  Google Scholar 

  9. 9.

    Pantalé O, Bacaria JL, Dalverny O, Rakotomalala R, Caperaa S (2004) 2D and 3D numerical models of metal cutting with damage effects. Comput Methods Appl Mech Eng 193:4383

    Article  MATH  Google Scholar 

  10. 10.

    Esteco Mode Frontier Documentation Version 4.3, 2007

  11. 11.

    Shaw MC (2013) Metal cutting principles 2E C. Oxford Science, Oxford

    Google Scholar 

  12. 12.

    Ng EG, Aspinwall DK, Brazil D, Monaghan J (1999) Modelling of temperature and forces when orthogonally machining hardened steel. Int J Mach Tools Manuf 39:885

    Article  Google Scholar 

  13. 13.

    Özel T (2003) Modeling of hard part machining: effect of insert edge preparation in CBN cutting tools. J Mater Process Technol 141:284

    Article  Google Scholar 

Download references

Author information

Affiliations

Authors

Corresponding author

Correspondence to Usama Umer.

Rights and permissions

Reprints and Permissions

About this article

Cite this article

Umer, U., Qudeiri, J.A., Hussein, H.A.M. et al. Multi-objective optimization of oblique turning operations using finite element model and genetic algorithm. Int J Adv Manuf Technol 71, 593–603 (2014). https://doi.org/10.1007/s00170-013-5503-y

Download citation

Keywords

  • Oblique turning
  • Finite element model
  • Multi-objective optimization