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Modeling and optimization of machining parameters to minimize surface roughness and maximize productivity when turning polytetrafluoroethylene (PTFE)

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Abstract

The objective of this work is to study the impact of the machining parameters (ap, f, and Vc) on the technological parameters, surface roughness criteria (Ra, Rz), and material removal rate (MRR) during the turning of polytetrafluoroethylene (PTFE) polymer. The machining tests were carried out using a square metal carbide insert in compliance with the Taguchi design (L27). ANOVA was used to determine the influence and contribution of machining parameters (ap, f, and Vc) on the output parameters (Ra, Rz, and MRR). It was indicated that the surface roughness and the material removal rate are strongly affected by the feed rate with contributions of 90.02, 91.81, and 49.22% for Ra, Rz, and MRR, respectively. The response surface methodology (RSM) and the artificial neural networks (ANN) approach were used for output technological parameter modeling to discern the most efficient one. Finally, the desirability function (DF) was used to determine optimal cutting parameters. The optimization was carried out using three approaches, which are quality, productivity, and the combination of quality and productivity. The results showed that the optimal parameters for minimizing roughness and maximizing MRR were found as ap = 2 mm, f = 0.126 mm/rev, and Vc = 270 m/min.

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  • 03 October 2022

    Springer Nature’s version of this paper was updated to present correct affiliation 2.

Abbreviations

ANOVA:

Analysis of variance

ANN:

Artificial neural network

RSM:

Response surface methodology

ap:

Depth of cut (mm)

Vc:

Cutting speed (m/min)

ƒ:

Feed rate (mm/rev)

cont %:

Contribution ratio (%)

DF:

Desirability function

F value,:

Ratio of mean square of regression model

R 2 :

Determination coefficient

Ra:

Arithmetic mean roughness (μm)

Rz:

Mean depth of roughness (μm)

MRR:

Material removal rate (cm3/min)

SS:

Sequential sum of squares

SC:

Sum of squares

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Acknowledgements

This work was achieved in the Advanced Technologies in Mechanical Production Research Laboratory (LRTAPM), Badji Mokhtar-Annaba University, Algeria. The authors would like to thank the personnel of Mechanics and Structures Research Laboratory (LMS), May 8th, 1945 University, Guelma, for their assistance, as well as the equipment used for the turning of PTFE.

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Authors and Affiliations

  1. Research Laboratory of Advanced Technologies in Mechanical Production “LRTAPM,” Department of Mechanical Engineering, Badji Mokhtar University, BP 12, 23000, Annaba, Algeria

    Afef Azzi & Lakhdar Boulanouar

  2. Research Centre in Industrial Technologies (CRTI), PO Box 64, Cheraga, 160141, Algiers, Algeria

    Afef Azzi & Alima Mebrek

  3. Structures and Mechanics Laboratory (LMS), Mechanical Engineering Department, May 8th, 1945 University, PO Box 401, 24000, Guelma, Algeria

    Aissa Laouisi & Mohamed Athmane Yallese

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  1. Afef Azzi
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  3. Aissa Laouisi
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Azzi, A., Boulanouar, L., Laouisi, A. et al. Modeling and optimization of machining parameters to minimize surface roughness and maximize productivity when turning polytetrafluoroethylene (PTFE). Int J Adv Manuf Technol 123, 407–430 (2022). https://doi.org/10.1007/s00170-022-10160-z

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