Development of Expert System for Estimation of Cutting Forces in Turning

Abstract

Cutting force generated during machining such as turning, drilling, milling and grinding newlinehas been the most effective way of understanding the machinability characteristics newlinesince, it directly affects the machined workpiece surface, tool life, power consumption newlineand dimensional accuracy. Further, it has been also observed that high cutting forces newlineresult in deterioration of fatigue life and increase in residual stress. Hence, it has been newlinethe challenge for the researchers to understand the reason behind increase in cutting newlineforces generated during machining of metals and alloys and to avoid excessive newlinedistortion. newlineGrowing demand for titanium due to its attractive properties such as superior strength to newlineweight ratios, fracture resistant characteristics, and their exceptional resistance to newlinecorrosion has made them viable in industrial as well as commercial applications, such as newlineaerospace industries, nuclear waste storage, automobile industries and surgical newlineimplantation. However, in spite of these properties titanium alloy is classified as newlinedifficult to machine materials because of its low modulus of elasticity, low thermal newlineconductivity and high chemical reactivity resulting in high tool vibration and high newlinecutting temperature has made the researchers to explore the machinability behaviour of newlineTi-6Al-4V. newlineIn the view of above facts, an attempt has been made to study the machinability of Ti- 6Al-4V in this dissertation. The main objective of the research is to determine the newlinefavourable machining conditions for minimizing the cutting force during machining of newlineTi-6Al-4V. Hence, orthogonal cutting experiments based on the results of Taguchi s newlinedesign of experiment, Response surface methodology, Desirability function approach, Artificial Neural Network (ANN), Fuzzy logic model, Finite element analysis and newlineExpert system has been developed to achieve this goal, because Taguchi s design of newlineexperiment, Response surface methodology, etc. are not experimental methods. newlineThe first part of the research discusses the influence of cutting paramete