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Procedia Manufacturing 00 (2017) 000–000
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Procedia Manufacturing 20 (2018) 517–522
Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia
2nd International Conference on Materials Manufacturing and Design Engineering
2nd International Conference on Materials Manufacturing and Design Engineering
An Alternate Machining Method for Hardened Automotive Gears
An Alternate Machining Method for Hardened Automotive Gears
a
c
Manufacturing Engineering
Society International
Conference
28-30 June
Debabrata Samantaraya
, Sanjay
Lakadebb, 2017,
AshokMESIC
Keche2017,
a
c
2017,
Vigo
(Pontevedra),
Spain
Debabrata Samantaraya , Sanjay Lakade , Ashok Keche
a,b
Pimpri Chinchwad College of Engineering, Sector-26, Pradhikaran, Nigdi, Pune-411044, Maharashtra, India
c
Maharashtra
Institute
of Technology,
Aurangabad-431028,
Pimpri Chinchwad
College of
Engineering,
Sector-26,
Pradhikaran, Nigdi,Maharashtra,
Pune-411044,India.
Maharashtra, India
a,b,c
c
Corresponding authors’
E-mail addresses:
sanjay.lakade@pccoepune.org,
Maharashtra
Instituted.samantaraya@yahoo.co.in,
of Technology, Aurangabad-431028,
Maharashtra, India. ashok.keche@mit.asia
a,b,c
Corresponding authors’ E-mail addresses: d.samantaraya@yahoo.co.in, sanjay.lakade@pccoepune.org, ashok.keche@mit.asia
a,b
Costing models for capacity optimization in Industry 4.0: Trade-off
between used capacity and operational efficiency
Abstract
Abstract
a
a,*
b
b
A. Santana
, P. Afonso
, A. Zanin
, R.automotive
Wernkegears
This paper describes an experimental
investigation
on hard turning
of disc type
made of 20Mn5Cr5 steel
hardened
60±2 HRC
grinding
are
conducted
by
using
PCBN
tools
on a CNC
turning centre
This
papertodescribes
an against
experimental
investigation
on
hard
turning
of
disc
type
automotive
gears
made
of 20Mn5Cr5
steel
a process. Experiments
University of Minho, 4800-058 Guimarães, Portugal
b
without using
coolant.
effectgrinding
of machining
parameters;
cutting
speed
(v
feed
rate (f)
and depth
of cut
(ap) on
the surface
hardened
to 60±2
HRCThe
against
process.
Experiments
are
conducted
by using
PCBN
tools on
a CNC
turning
centre
Unochapecó,
89809-000
Chapecó,
SC,
c),Brazil
roughness
Ra (µm)
is analyzed
andofoptimized
the help cutting
of Taguchi
design
experiment
(DOE),
(S/N)
ratio
without using
coolant.
The effect
machiningwith
parameters;
speed
(vc), of
feed
rate (f) and
depth signal
of cut to(anoise
surface
p) on the
and
analysis
variance
(ANOVA)
methods.with
Thethe
surface
quality,
process
some economical
and (S/N)
ecological
roughness
Ra of
(µm)
is analyzed
and optimized
help of
Taguchi
designcharacteristics,
of experiment (DOE),
signal to noise
ratio
features
of theofhard
turning(ANOVA)
are analyzed
and compared
with the
grinding.
and
analysis
variance
methods.
The surface
quality,
process characteristics, some economical and ecological
Abstract
features of the hard turning are analyzed and compared with the grinding.
© 2017The Authors. Published by Elsevier B.V.
Under
concept
of "Industry
4.0",
production
processes will be pushed to be increasingly interconnected,
©
2018 the
The Authors.
Published
by Elsevier
B.V.
Peer-review
under responsibility
the scientific
© 2017The Authors.
Published
byofElsevier
B.V. committee of the 2nd International Conference on Materials
Peer-review
under
responsibility
of
the
scientific
committee
of
themuch
2nd International
Conference
oncontext,
Materialscapacity
Manufacturing
and
information
based
on
a
real
time
basis
and,
necessarily,
efficient.
In this
optimization
Manufacturing
andresponsibility
Design Engineering.
Peer-review
under
of the scientific committee
of more
the 2nd
International
Conference
on Materials
Design
Engineering.
goes
beyond
the traditional aim of capacity maximization, contributing also for organization’s profitability and value.
Manufacturing and Design Engineering.
Indeed,
leanPCBN;
management
and
continuous
approaches
suggest capacity optimization instead of
Keywords:
Hard; Turning;
Grinding;
Taguchi;improvement
ANOVA; Automotive;
Gear
maximization.
The
study
of
capacity
optimization
and
costing
models
is
an important research topic that deserves
Keywords: PCBN; Hard; Turning; Grinding; Taguchi; ANOVA; Automotive; Gear
contributions from both the practical and theoretical perspectives. This paper presents and discusses a mathematical
model
for capacity management based on different costing models (ABC and TDABC). A generic model has been
1. Introduction
developed
and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
1. Introduction
value.
The
trade-off
capacity
vs operational
efficiencyofis hardened
highlighted
andwith
it ishardness
shown that
capacity
Hard
Turning
is one
of themaximization
emerging technologies
for machining
steels
values
in the
optimization
might
hide
operational
inefficiency.
range
of Turning
48 to
68 is
HRC
single
point
cutting tool.forThe
popularity
hard turning
increasing
day-by-day
Hard
oneusing
of thea emerging
technologies
machining
of of
hardened
steelsiswith
hardness
values in and
the
©range
The
Published
bya Elsevier
B.V.process,
it 2017
is becoming
an important
particularly
in automotive
bearing
manufacturing
industries.
of
48Authors.
to 68
HRC
usingmanufacturing
single point
cutting tool.
The popularity
of hardand
turning
is increasing
day-by-day
and
Peer-review
under
of theused
scientific
committee
offinishing
the Manufacturing
Engineering
Societymanufacturing
International
Traditionally,
grinding
has manufacturing
been
as aprocess,
standard
process
for the
of hardenedConference
steels,
but
it is becoming
anresponsibility
important
particularly
in
automotive
andmachining
bearing
industries.
2017.
technological advances
fieldused
of machine
tools and
cuttingprocess
tool materials
made hard
turning possible
on
Traditionally,
grinding in
hasthe
been
as a standard
finishing
for the have
machining
of hardened
steels, but
modern lathesadvances
as an attractive
alternative
to replace
conventional
grindinghave
applications
[1-5].
The possible
factors that
technological
in the field
of machine
toolsmany
and cutting
tool materials
made hard
turning
on
Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency
brought lathes
the attention
of industries
towards
turning
are; substantial
reduction of[1-5].
manufacturing
modern
as an attractive
alternative
to hard
replace
manyprocess
conventional
grinding applications
The factorscosts,
that
reductionthe
in attention
production
time, achievement
of comparable
or better
finish
and geometrical
accuracies
and
brought
of industries
towards hard
turning process
are; surface
substantial
reduction
of manufacturing
costs,
or
complete
elimination
of
environmentally
harmful
cooling
media
[6-8].
Davim
and
Figueira
[9]
reduction
in
production
time,
achievement
of
comparable
or
better
surface
finish
and
geometrical
accuracies
and
1. Introduction
reported thatorit is
possibleelimination
to obtain a surface
roughness of harmful
Ra < 0.8µm
in hard
turning
the suitable
choice[9]
of
reduction
complete
of environmentally
cooling
media
[6-8].with
Davim
and Figueira
reported
that
it
is
possible
to
obtain
a
surface
roughness
of
Ra
<
0.8µm
in
hard
turning
with
the
suitable
choice
The cost of idle capacity is a fundamental information for companies and their management of extreme importanceof
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
2351-9789© 2017 The Authors. Published by Elsevier B.V.
in
several ways:
of production,
available
hours of
manufacturing,
etc.Conference
The management
of Manufacturing
the idle capacity
Peer-review
under tons
responsibility
of the scientific
committee
of the
2nd International
on Materials
and
2351-9789© 2017 The Authors. Published by Elsevier B.V.
* PauloEngineering.
Afonso.
Tel.:responsibility
+351 253 510 of
761;
+351 253
604 741 of the 2nd International Conference on Materials Manufacturing and
Design
Peer-review
under
thefax:
scientific
committee
E-mail
address:
psafonso@dps.uminho.pt
Design Engineering.
2351-9789 © 2017 The Authors. Published by Elsevier B.V.
Peer-review
under
of the
scientificbycommittee
the Manufacturing Engineering Society International Conference 2017.
2351-9789 ©
2018responsibility
The Authors.
Published
Elsevier of
B.V.
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Design Engineering.
10.1016/j.promfg.2018.02.077
Debabrata Samantaraya et al. / Procedia Manufacturing 20 (2018) 517–522
Author name / Procedia Manufacturing 00 (2017) 000–000
518
2
cutting parameters. Yallesea et al. [10] reported that grinding comparable surface finish can be achieved in hard
turning of 100Cr6-tempered bearing steel with CBN tool. Kishawy and Elbestawi [11] investigated the surface
integrity of AISI D2 steel of 62 HRC with cutting speeds in the range 140–500m/min, feeds 0.05–0.2mm/rev, depths
of cut 0.2–0.6mm using the PCBN tools with edge preparations and reported that at the cutting speeds above
350m/min, the surface roughness increased with increase in tool wear due to material side flow. Therefore, an
attempt has been made in the present research to find out the optimum combination of cutting parameters that would
yield minimum surface roughness using PCBN tool.
The majority of the researchers have carried out their researches on hard turning on the various steel material test
pieces (round bars). However, in the present research, authors have chosen an actual part – an automotive disc type
gear as the research object, hence the results obtained from this research can be used as a ready reference in the
industries engaged in the manufacturing of similar parts.
2. Experimental Details
2.1. Workpiece material chemical composition and dimensional specification
The chemical composition of workpice material 20Mn5Cr5 is given in Table 1, which is hardened to 60±2 HRc.
The workpiece photo and drawing with dimensional specifications are shown in Fig. 1.
Table 1: Chemical composition of 20Mn5Cr5 Steel (wt %)
C
Si
Mn
0.17-0.22
0.15-0.35
1.0-1.4
a)
b)
c)
Cr
1.0-1.3
P
0.035
S
0.035
d)
Fig. 1. Workpiece & its dimensional specification: (a) RH side view, (b) Front view, (c) LH side view, (d) part drawing
The experiments were conducted on Jyoti CNC Turning Centre (FM200 Model, spindle power 6.6KW and
spindle speed 5500 RPM) with PCBN insert of ISO designation TNMA 160408 BN350 (Sumitomo make) in dry
condition. The inserts were mounted on ISO tool holder PTFNL 16 S32S. The combination of the insert and the tool
holder resulted an axial rake angle  = -6° (negative), cutting edge inclination angle (radial rake)  = -10° (negative)
and cutting edge approach angle Kr = 91°. Mitutoyo make surface tester was used for measuring surface roughnessRa (µm). The surface roughness measurements were repeated three times at three different zones positioned at 120°
apart for each turned workpiece and the average of three readings are given in Table 3. Klingelnberg P–40 gear
measuring and inspection machine was used for measuring the cylindricity, circularity and straightness of the
machined bore hole dia. 59.6H7. Three sets of cutting speeds (vc), feed rates (f) and depth of cut (ap) were chosen
within the specified intervals recommended by the cutting tool manufacturer and arranged in three levels in Table 2.
Table 2: Machining parameters and their levels for hard turning of bore hole dia.59.6H7
Level
Cutting Speed
Feed rate
Depth of cut
(m/min.)
(mm/rev.)
(mm)
1
110
0.05
0.08
2
130
0.07
0.10
3
150
0.09
0.12
Debabrata Samantaraya et al. / Procedia Manufacturing 20 (2018) 517–522
Author name / Procedia Manufacturing00 (2017) 000–000
519
3
3. Result and Discussion
3.1. Effect of machining parameters on surface roughness
In this experiment, Taguchi L9 orthogonal array design of experiment and Signal-to-Noise (S/N) ratio
methods were applied to find out optimal combination of cutting parameters for obtaining a minimal surface
roughness (Ra). Nine experimental runs were conducted with three different combinations of cutting parameters and
resulted surface roughnesses are arranged in Table 3. While analyzing S/N ratio, three categories of the quality
characteristics were used, i.e. the-smaller-the-better, the-higher-the-better, and the nominal-the-better. A
greater S/N ratio represents the optimal process parameter levels, regardless of the category of the quality
characteristic selected. For obtaining a minimal surface roughness, the "the-smaller-the-better" quality
characteristic was considered and the S/N ratio is calculated according to the following equation (1);
S
 1 n 2
= −10. lg  y  (1), Where n is the number of replication and yi is measured value of output variables.
N
 n i=1 i 
The means of S/N ratios are calculated for each level of control parameters and shown in Table 4. The
ranks are assigned to the values, which are the difference between maximum and minimum mean S/N ratio
values. It can be seen from the Table 4, the feed rate has the highest rank followed by the depth of cut and
cutting speed. This indicates that feed rate has the highest influence on the surface roughness followed by
the depth of cut and cutting speed. The main effect plot (Fig. 2) shows that feed rate has the greatest significance
on the surface roughness followed by the depth of cut and cutting speed. The S/N ratio response table and the
main effect plots show that minimal surface roughness can be achieved with the cutting speed at level 2,
feed rate and depth of cut at level 1, as these levels have the highest mean S/N ratios. Therefore, the optimal
combination of machining parameters is A2-B1-C1, i.e. cutting speed (vc) 130m/min, feed rate (f) 0.05mm/rev. and
depth of cut (ap) 0.08mm. Though the S/N ratio response table indicates the degree of influence of cutting
parameters on the surface roughness, it does not specify the percentage of contribution of individual cutting
parameters. Therefore, one-way analysis of variation (ANOVA) is conducted (Table 5). A low P-value indicates
statistical significance of the corresponding parameter on the response factor. ANOVA shows that the feed rate
(57%) has the highest statistical significant effect on surface roughness followed by the depth of cut (42.18%) and
the cutting speed (0.46%) has the least significance on surface roughness.
Table 3: Experimental results for surface roughness
Test Run No.
Cutting Speed (m/min.) Feed (mm/rev.) Depth of cut (mm) Surface Roughness Ra (m)
S/N Ratio (dB)
1
110
0.05
0.08
0.299
10.487
2
110
0.07
0.10
0.618
4.180
3
110
0.09
0.12
0.959
0.364
4
130
0.05
0.10
0.373
8.566
5
130
0.07
0.12
0.765
2.327
6
130
0.09
0.08
0.516
5.747
7
150
0.05
0.12
0.486
6.267
8
150
0.07
0.08
0.425
7.432
9
150
0.09
0.10
0.760
2.384
Table 4: S/N ratio response table for surface roughness
Symbol
Cutting parameters
Mean S/N ratio (dB)
Rank
Highest mean
Level 1
Level 2
Level 3
Max-Min
A
Cutting speed
5.010
5.547
5.361
0.536
3
A2
B
Feed rate
8.440
4.646
2.831
5.608
1
B1
C
Depth of cut
7.889
5.043
2.986
4.903
2
C1
Table 5: Results of ANOVA for surface roughness
Symbol
Cutting parameters Degrees of freedom Sum of squares Mean squares
F
P
Contribution (%)
A
Cutting speed
2
0.40
0.20
1.33
0.4292
0.46
B
Feed rate
2
49.14
24.57
163.80 0.0061
57
C
Depth of cut
2
36.37
18.185
121.23 0.0082
42.18
Error
2
0.30
0.15
Total
8
86.210
Debabrata
Samantaraya
al. / Procedia 00
Manufacturing
20 (2018) 517–522
Author name
/ Procedia et
Manufacturing
(2017) 000–000
4520
Fig. 2. Main effect plot for Surface roughness (Ra)
3.2. Process characteristics and economy analysis comparison: hard turning vs. grinding
The surface roughness (Ra) and the geometrical accuracies – cylindricity, circularity and straightness are the
major performance characteristics and represent the process capability of a machining process. For comparing these
characteristics, a batch size of 250 numbers of gears was machined each in hard turning and grinding in a factory
production line. Finish hard turning is carried out with the optimal combination of cutting parameters
(vc=130m/min., f=0.05mm/rev., ap=0.08mm) that had resulted from Taguchi DOE and S/N ratio methods as
discussed in preceding section 3.1. HMT cylindrical grinding machine was used for bore grinding. The machining
parameters applied in hard turning and grinding are given in Table 6.
Table 6: Machining parameters applied for the machining of bore hole in grinding and hard turning
Grinding
Hard turning
Roughing
Finishing
vc = 150 m/min
vc = 130 m/min
Internal grinding:
vc = 30 m/sec, Wheel RPM = 10,000, f L (roughing) =1.5 m/min., f L (finishing) =1 m/min.,
f = 0.15 mm/rev
f = 0.05 mm/rev
ap = 0.24 mm
ap = 0.08 mm
Workpiece RPM = 200, Stock allowance = 0.32mm
3.3. Surface roughness (Ra) and geometrical accuracy comparison
Surface roughness achieved in both the processes (Fig. 4a) shows that though average surface roughness
produced in hard turning (0.56µm) is little higher than that of grinding (0.37µm), but it was well within the
prescribed requirement (0.8µm). Therefore, hard turning is capable of producing comparable surface roughness with
grinding. The comparison of geometrical profiles and accuracies achieved in both the process are shown in Fig. 3
and Fig. 4b respectively. It is observed from the column diagrams (Fig. 4b) that circularity, cylindricity, and
straightness obtained in hard turning are 3, 3, 4 microns respectively against 9 microns each in grinding. These
results imply that hard turning is capable of producing better geometrical accuracies in comparison to grinding.
Machining Process
Circularity
Cylindricity
Straightness
Grinding
Hard turning
Fig. 3. Comparison of geometrical accuracy profiles in hard turning and grinding
Debabrata Samantaraya et al. / Procedia Manufacturing 20 (2018) 517–522
Author name / Procedia Manufacturing00 (2017) 000–000
0.8
1
0.56
Geometrical
accuracies (µm)
b)
Surface
roughness
Ra(µm)
a)
521
5
0.37
0
Specified requirement
Hard turning
10
9
10
10
3
9
10
9
4
3
0
Circularity
Cylindricity Straightness
Specified requirement
Grinding
Hard turning
Grinding
Fig. 4. Comparison of process characteristics in hard turning and grinding (a) surface roughness; (b) geometrical accuracies
3.4. Economy Analysis: manufacturing
nufacturing time and manufacturing cost
2
3.4
2.86
4
1.67
0.54 0.11
Time/piece (%)
Time/piece
(min)
The objective to implement any newer machining process in a factory production line depends on few crucial
parameters; its productivity, flexibility, impact on the environment and the most important parameter is its
it overall
cost impact. Therefore, a comparative economy analysis is required to examine the potential of implementation of
hard turning in place of grinding in a factory production line.
The manufacturing time of a part in a particular production process comprises of two components; namely setup
preparation time and cycle time. Setup preparation time consists of time taken for setting up the fixture,
fixture cutting
tools, setting gauges and measuring
ring instruments.
instruments Cycle time includes the times consumed for workpiece loading and
unloading, machining, measurement and inspection. Grinding process for bore holes is a time consuming process
which requires roughing, finishing, spark out operations and wheel dressing at each cycle.. Whereas, hard turning
can be accomplished by one rough and one finish depth of cut only. The setup preparation
paration time in grinding was 135
minutes as against 25 minutes in hard turning.
turning The setup preparation time (Ts) per piece is calculated by dividing the
total time (Tt) with batch size (n). The various components of manufacturing time per piece is presented in column
diagram (Fig. 5),
time of hard turning were
), which shows that the setup preparation time and cycle
c
re 20% and 58%
58 of
grinding
rinding respectively. These results imply that total manufacturing time of hard turning is 52% of grinding which is
significantly lower than that of grinding.
b)
a)
1.78
0
Set up prep.
time
Grinding
Cycle
Total
time
time
Hard turning
100
100
100
58.4
100
20.4
50
52.4
0
Set up prep.
Cycle
Total
time
time
time
Grinding
Hard turning
Fig. 5. Comparison of manufacturing times in grinding and hard turning:: (a) times in minutes, (b) times in percentage
365.9
400
300
200
100
0
250
90.7
57.1 22.3 58.8 31.4
144.4
Operator Machining Production Total
wages
mfg.cost
Grinding
Hard turning
Cost/piece ( %)
Cost/piece (INR)
Manufacturing cost comprises of three types of cost components namely operator wages, machining cost, and
production cost. The manufacturing costt distribution in both the processes is presented in column diagram Fig. 6,
which shows that the operator wage, machining time, and production cost of hard turning is 36%, 39%, and 53% of
grinding respectively. Therefore, the total manufacturing cost of hard
ha turning is 40% of grinding.
a)
b)
100
100
50
100
36.3
39.1
100
100
53.4
39.5
0
Operator MachiningProduction Total mfg.
wages
cost
Grinding
Hard turning
Fig. 6. Comparison of manufacturing costs in grinding and hard turning:: (a) cost per piece in INR, (b) cost per piece in percentage
522
6
Debabrata Samantaraya et al. / Procedia Manufacturing 20 (2018) 517–522
Author name / Procedia Manufacturing 00 (2017) 000–000
3.5. Impact on environment
Grinding as a machining process creates hazardous waste when the broken off abrasive particles and binding
materials of grinding wheels mix with the coolant and create mud like residues [12]. These residues and used
coolants are dangerous waste which cannot be reused and recycled and incurs additional expenditure for its handling
and disposal. Therefore, grinding is not an environment-friendly machining process. In contrast to grinding, it is
possible to machine a part using the PCBN tool without coolant in hard turning, making it a favorable green
machining process by eliminating the harmful effect of coolant on the environment.
4. Conclusion
Based on the experimental results and theoretical discussion, following conclusions can be drawn.
• With the help of Taguchi method, process optimization can be possible with less number of experimental runs
and the results can be extrapolated to a larger lot size in a factory production system.
• The feed rate (57%) has the greatest influence on surface roughness followed by the depth of cut (42.18%).
Cutting speed (0.46%) has insignificant influence on surface roughness.
• It is observed that hard turning can provide a comparable and even better geometrical accuracies and surface
roughness in comparison to grinding.
• The manufacturing time and manufacturing cost of hard turning is 52% of grinding. This leads to 60% saving in
manufacturing cost in hard turning in contrast to grinding.
• Hard turning is possible to perform without coolant which makes it an environment-friendly process by
eliminating the harmful effect of coolant on the environment.
• Hard turning has a greater potential as an alternative machining method to traditional grinding process for the
components such as automotive gears which have short machining lengths, different shapes and forms.
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