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Browsing Articles by Author "ABIDI Youcef"

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    Analysis of the compromise between cutting tool life, productivity and roughness during turning of C45 hardened steel
    (PRODUCTION ENGINEERING ARCHIVES, 2021) ABIDI Youcef
    Tool wear and surface roughness as performance indexes are considered to be the most important in terms of hardened materials’ machinability. The best combination of cutting parameters which en hances the compromise between tool life, productivity and machined surface quality contribute to benefice on production cost, which makes manufacturing industry interested in it. The aim of this research is to investigate the life of ceramic cutting tool and machining productivity together with surface roughness during turning of hardened steel C45, with focus on the selection of the optimal cutting parameter combination. The experiments are carried out based on uni-factorial planning meth odology of cutting speeds and feed rates. The results show that the mixed ceramic tool is suitable for turning hardened steel C45 (40 HRC) and the conclusion is that it performed well in terms of tool life, productivity and surface quality at a combination of cutting speed (200 m/min), feed (0.08 mm/rev) and depth of cut (0.3 mm). Additionally, a tool life model has been proposed which is presented very high coefficient of determination.
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    Correlation Analysis between Tool Wear, Roughness and Cutting Vibration in Turning of Hardened Steel
    (Engineering Transactions, 2021) ABIDI Youcef; BOULANOUAR Lakhdar (Co-Auteur)
    Hard machining is a process that has become highly recommended for replacing grinding in the manufacturing industry. This is due to its ability to machine complex shapes with reduced production costs by reducing the machining time and being an ecological process. Three technological parameters determine the quality and productivity generated from this process: cutting vibration, surface roughness and tool wear. Therefore, the analysis of the correlation between them is very important. In the present investigation, the analysis of the correlation between cutting vibration, surface roughness and tool wear during a dry machining of hardened steel with a mixed ceramic tool is conducted in order to control these parameters online. This analysis is validated by developing predictive mathematical models. To neutralize the effect of cutting parameters, a combination of parameters such as cutting speed, feed rate and depth of cut to be used in the experimental tests is selected from the literature based on a quality-productivity optimum performance. In the early stage, the effect of machining time on the three technological parameters is studied, then assessed by developing predictive mathematical models. In the second stage, an experimental and statistical analyses such as the Pearson and Spearman correlation methods are employed to determine correlations between tool wear, surface roughness and cutting vibration. Each parameter is compared with the other two. The models and their validations are developed using the Minitab 16 tool, and the predictions are obtained with desirable deviations. The examination of the outcomes from the first stage reveals that the machining time has a significant effect on the three parameters. The regression models are found to be satisfactory in predicting each technological parameter. In the second stage, the results show a strong cor relation between tool wear and cutting vibration, confirmed by the high Pearson and Spearman coefficients. The correlations between surface roughness and tool wear or the cutting vibra tion are strong only when the flank wear Vb is inferior 0.3 mm (which is required by the ISO standard). The regression models are developed with a desirable coefficient of regression (R2). The novelty of this work lies in the fact that we consider the cutting vibration as a response generated the during cutting process and not as a variable affecting the other technological parameters. This was rarely studied in previous researches.
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    MACHINING PERFORMANCE ANALYSIS OF CUTTING TOOL MATERIALS IN HARD TURN-ING OF BEARING STEEL
    (ACADEMIC JOURNAL OF MANUFACTURING ENGINEERING, 2021) ABIDI Youcef
    The objective of this experimental study is to evaluate the performance of three tool materials (mixed ceramic (CC650), PVD-coated carbide tool (GC1025) and CVD-coated carbide tool (GC4015)) during hard turning process of bearing steel 100Cr6 (66HRC) under dry environment. To do this, long-term tests used out to determine the tools life, productivity and machined surface quality in relationship with variation of the cutting speed and feed. The admissible parametric of cutting conditions has been obtained in order to reach a compromise tool life, its productivity and machined surface quality of part. Results showed that cutting speed is the most important factor affecting tool life but surface roughness was mainly influended by feed. Second order regression models was developed to find out the relationships between cutting speed and tools life time in the one hand and the correlation between tools life time and feed rate on the other hand. The results were compared to the litterature. For comparative study, the results showed that ceramic tool has been characterized by a good productivity and better surface quality compared to PVD-coated carbide tool. The latter was in turn more efficient than CVD coated carbide tool, which beyond the cutting speed 75 m/min was unproductive
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    Relationship between surface roughness and chip morphology when turning hardened steel
    (PRODUCTION ENGINEERING ARCHIVES, 2020) ABIDI Youcef
    Hard machining is a process which has become highly recommended in manufacturing industry to replace grinding and perform production. The important technological parameters that determine this process are tool wear, machined surface roughness, cutting force and morphology of the removed chip. In this work, an attempt has been made to analyse the morphology and form of chip removed during turning of hardened steel AISI 1045 (40HRC) with mixed ceramic tool type CC650. Using a Taguchi plan L9, whose factors are cutting speed and feed rate with three levels for each. Macroscopic and microscopic results of chip morphology were correlated with these two cutting parameters additional to surface roughness. Sufficient experimental results were obtained using the mixed ceramic tool when turning of hardened steel AISI 1045 (40HRC) at high cutting speeds. Roughness of machined surface confirmed that it is influenced by feed rate. Chips show a sawtooth shape for all combinations of the experimental plan used. The chip form changed with cutting parameters variation and given an important indicator of suraface quality for industriel. Having the indicators on the surface quality from simple control of chip without stopping machining give an important advantage in order to maximize production and reduce costs.