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Research on feasible region of specific cutting energy and surface roughness in high-speed dry milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts

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Abstract 

Existing researches on coated tools do not provide predicted data about machining performance while exploring their changing rules. Meanwhile, the traditional cutting process parameters neither guarantees the surface quality of the 30CrMnSiNi2A nor attains high material removal rate (MRR). Accurate control and prediction of workpiece three-dimensional surface roughness (Sq) and specific cutting energy consumption (SCEC) play an important role in improving the quality, reducing the cost of workpieces, and improving the processing efficiency. In this paper, according to the new SCEC geometric calculation approach and the influence of measuring position on Sq, the SCEC and Sq values can be accurately obtained. Then, based on the idea of the fitting formula, the influence of cutting parameters on SCEC and Sq in high-speed dry (HSD) milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts is analyzed. Finally, the SCEC and Sq prediction models considering coating type, cutting speed, feed per tooth, and cutting width are established by using the XGBoost algorithm. The R2 values of SCEC and Sq are 0.92465 and 0.91527, respectively, indicating that the model has a good prediction effect on experimental data. The feasibility of HSD milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts is verified by analyzing SCEC, Sq, and cutting temperature, which provides an experimental basis for high efficiency and high precision machining of 30CrMnSiNi2A steel.

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Acknowledgements

The authors gratefully acknowledge the reviewers and editors for their insightful comments.

Funding

This work is supported by the National Key R&D Program of China (2020YFB2010500).

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Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing, 400044, China

    Jin Zhang, Xinzhen Kang, Huajun Cao, Hao Yi, Xuefeng Huang, Chengchao Li & Guibao Tao

  2. State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing, 400044, China

    Jin Zhang, Xinzhen Kang, Huajun Cao, Hao Yi, Xuefeng Huang, Chengchao Li & Guibao Tao

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  1. Jin Zhang
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Contributions

Jin Zhang: conceptualization; investigation; methodology; validation; roles/writing—original draft. Xinzhen Kang: software; data curation. Huajun Cao: supervision; writing—review and editing; project administration; funding acquisition; resources. Hao Yi: Writing—review and editing. Xuefeng Huang: visualization. Chengchao Li: data curation. Guibao Tao: major revision opinion; project administration; funding acquisition; resources.

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Correspondence to Guibao Tao.

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Appendices

Appendix 1

Table 8

Table 8 The cutting parameters for CVD and PVD of SCEC experimental results
Full size table

Appendix 2

The experiment results of surface roughness by CVD and PVD inserts.

Table 9

Table 9 The experiment results of surface roughness by CVD inserts
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Appendix 3

Table 10

Table 10 Explanation of variables
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Zhang, J., Kang, X., Cao, H. et al. Research on feasible region of specific cutting energy and surface roughness in high-speed dry milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts. Int J Adv Manuf Technol 125, 133–155 (2023). https://doi.org/10.1007/s00170-022-10647-9

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