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    Design optimization of cutting parameters when turning hardened AISI 4140 steel (63 HRC) with Al2O3+TiCN mixed ceramic tool
    (Elsevier Sci Ltd, 2007) Aslan, Ersan; Camuscu, Necip; Birgoren, Burak
    Due to their high hardness and wear resistance, Al2O3-based ceramics are one of the most suitable cutting tool materials for machining hardened steels. However, their high degree of brittleness usually leads to inconsistent results and sudden catastrophic failures. This necessitates a process optimization when machining hardened steels with Al2O3 based ceramic cutting tools. The present paper outlines an experimental study to achieve this by employing Taguchi techniques. Combined effects of three cutting parameters, namely cutting speed, feed rate and depth of cut on two performance measures, flank wear (VB) and surface roughness (R-a), were investigated employing an orthogonal array and the analysis of variance (ANOVA). Optimal cutting parameters for each performance measure were obtained; also the relationship between the parameters and the performance measures were determined using multiple linear regression. (c) 2006 Elsevier Ltd. All rights reserved.
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    A numerical model to determine temperature distribution in orthogonal metal cutting
    (Elsevier Science Sa, 2006) Doğu, Yahya; Aslan, Ersan; Camuscu, Necip
    In this study, a thermal analysis model is developed to determine temperature distribution in orthogonal metal cutting using finite elements method. The model calculates the temperature distribution as a function of heat generation. The heat generation was introduced in the primary deformation zone, the secondary deformation zone and along the sliding frictional zone at the tool-chip interface, as well. The location and shapes of these zones was determined based on the literature work done so far and the model results. The temperature dependency of material properties was included in the model. A series of thermal simulations have been performed, and the value and location of maximum temperature have been determined for various cutting conditions. The comparison of the simulations with earlier works gave promising trend for the presented model. The thermal aspects of metal cutting as a result of the model findings were discussed. (c) 2005 Elsevier B.V. All rights reserved.
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    Tool wear evaluation by vibration analysis during end milling of AISI D3 cold work tool steel with 35 HRC hardness
    (Elsevier Sci Ltd, 2007) Orhan, Sadettin; Er, Ali Osman; Camuscu, Necip; Aslan, Ersan
    In this study, the relationship between vibration and tool wear was investigated during end milling. For this purpose, a series of experiment were conducted in a vertical milling machine. An indexable CBN insert and AISI D3 cold work tool steel hardened to 35 HRC were used as material twin in the experiments. The vibration was measured only in the machining direction, which has more dominant signals than in the other two directions. The measurements were taken by using an acceleration sensor assembled on a machinery analyzer. Tool wear was measured by a toolmaker's microscope. It was observed that there was an increase in vibration amplitude with increasing tool wears. This situation was evident especially by monitoring vibration of displacement type. It was also observed that the first three multiplies of tooth passing frequency (1 x, 2 x, 3 x) gave the best information about the tool wear. Results showed that there was no considerable increase in the vibration amplitude until a flank wear value of 160 mu m was reached, above which the vibration amplitude increased significantly. (C) 2006 Elsevier Ltd. All rights reserved.