A Multi-Response Optimization of Thrust Forces , Torques , and the Power of Tapping Operations by Cooling Air in Reinforced and Unreinforced Polyamide PA 66

The use of cooling air during machining is an environmentally conscious procedure, and its applicability to different processes is a research priority. We studied tapping operations, an important operation in the assembly process, using cooling air with unreinforced polyamide (PA66) and polyamide reinforced with glass fiber (PA66-GF30). These materials are widely used in industry, but their behavior with respect to tapping has not been studied. We analyze the outcomes regarding the thrust force, torque, and power at cutting speeds between 15 and 60 m/min. The experimental tests were executed using cooling air at 22 ◦C, 2 ◦C, and −18 ◦C in dry conditions. The M12 × 1.75 mm taps were high-speed steel, with cobalt as the base material and coatings of TiN and AlCrN. To identify the more influential factors, an analysis of variance was performed, along with multi-response optimization to identify the desirability values. This optimization shows that the optimum for PA66can be found in environments close to 3 ◦C, while the optimum for PA66-GF30 is found at the minimal temperature studied (−18 ◦C). Thus, cooling air can be considered an adequate procedure for tapping operations, to increase the sustainability of the manufacturing processes.

[1]  Mozammel Mia,et al.  Multi-response optimization of end milling parameters under through-tool cryogenic cooling condition , 2017 .

[2]  V. Barnett,et al.  Applied Linear Statistical Models , 1975 .

[3]  Steven R Schmid Kalpakjian,et al.  Manufacturing Engineering and Technology , 1991 .

[4]  Sang-Bing Tsai,et al.  Establishing a criteria system for green production , 2015 .

[5]  A. G. Olabi,et al.  Optimization of different welding processes using statistical and numerical approaches - A reference guide , 2008, Adv. Eng. Softw..

[6]  D. Kurniawan,et al.  Machining parameters effect in dry turning of AISI 316L stainless steel using coated carbide tools , 2017 .

[7]  Jin Huang,et al.  Mathematical Modeling and a Hybrid NSGA-II Algorithm for Process Planning Problem Considering Machining Cost and Carbon Emission , 2017 .

[8]  V. Tagliaferri,et al.  Machining of glass fiber reinforced polyamide , 2007 .

[9]  J. Paulo Davim,et al.  Machinability study on precision turning of PA66 polyamide with and without glass fiber reinforcing , 2009 .

[10]  Dry Sliding Behaviour of AlCrN and TiN Coatings , 2012 .

[11]  Rosario Domingo,et al.  A Sustainable Evaluation of Drilling Parameters for PEEK-GF30 , 2013, Materials.

[12]  Rosario Domingo,et al.  The Formation of Saw Toothed Chip in a Titanium Alloy: Influence of Constitutive Models , 2011 .

[13]  Vimal Dhokia,et al.  Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids , 2012 .

[14]  A. G. Jaharah,et al.  Effect of chilled air on tool wear and workpiece quality during milling of carbon fibre-reinforced plastic , 2013 .

[15]  M. M. Marín,et al.  Selection of Cutting Inserts in Dry Machining for Reducing Energy Consumption and CO 2 Emissions , 2015 .

[16]  J. Davim,et al.  Investigations on the drilling process of unreinforced and reinforced polyamides using Taguchi method , 2013 .

[17]  K. A. Padmanabhan,et al.  Comparison of TiAlN, AlCrN, and AlCrN/TiAlN coatings for cutting-tool applications , 2014, International Journal of Minerals, Metallurgy, and Materials.

[18]  Giacomo Copani,et al.  Sustainable Micro-Manufacturing of Micro-Components via Micro Electrical Discharge Machining , 2011 .

[19]  R. Domingo,et al.  Influence of tool cooling on thrust forces in tapping operations of reinforced polyamide , 2017 .

[20]  G. Derringer,et al.  Simultaneous Optimization of Several Response Variables , 1980 .

[21]  Pil-Ho Lee,et al.  Experimental characterization of micro-grinding process using compressed chilly air , 2011 .

[22]  Denni Kurniawan,et al.  Optimizing Power Consumption for Sustainable Dry Turning of Treated Aluminum Alloy , 2015 .

[23]  John W. Sutherland,et al.  Investigation of thread tapping load characteristics through mechanistics modeling and experimentation , 2002 .

[24]  R. Domingo,et al.  Determination of Energy during the Dry Drilling of PEEK GF30 Considering the Effect of Torque , 2013 .

[25]  E. Ekici,et al.  An investigation of the effects of cutting parameters and graphite reinforcement on quality characteristics during the drilling of Al/10B4C composites , 2017 .

[26]  Asif Iqbal,et al.  Refrigerated cooling air cutting of difficult-to-cut materials , 2007 .

[27]  Jie Liu,et al.  On temperatures and tool wear in machining hypereutectic Al–Si alloys with vortex-tube cooling , 2007 .

[28]  M. Silva,et al.  Analysis of tapping process in three types of cast iron , 2016 .

[29]  S. Yuan,et al.  Effects of cooling air temperature on cryogenic machining of Ti–6Al–4V alloy , 2011 .

[30]  E.J.A. Armarego,et al.  Predictive Cutting Models for the Forces and Torque in Machine Tapping with Straight Flute Taps , 2002 .

[31]  I. Korkut,et al.  The effect of cryogenic treatment on tapping , 2013 .

[32]  M. Dargusch,et al.  Machining Ti–6Al–4V alloy with cryogenic compressed air cooling , 2010 .

[33]  Xianting Zeng,et al.  Oxidation resistance of TiN, CrN, TiAlN and CrAlN coatings deposited by lateral rotating cathode arc , 2009 .