Experimental Investigations of Process Parameters Influence on Surface Roughness in Deep Cold Rolling of AISI 4140 Steel

Prabhu, P R and Kulkarni, S M and Sharma , S S (2012) Experimental Investigations of Process Parameters Influence on Surface Roughness in Deep Cold Rolling of AISI 4140 Steel. International Journal of Research in Engineering and Technology, 1 (3). pp. 159-163. ISSN 2277 – 4378

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Abstract

Deep cold rolling (DCR) process is a post-machining operation in which the surface irregularities of workpiece are compressed by the application of a ball, which produces a smooth compact surface and simultaneously induces compressive residual stress. In the present study, an attempt has been made to investigate the effect of process parameters (ball diameter, rolling force, initial roughness of the workpiece and number of tool passes) on surface roughness in deep cold rolling of AISI 4140 steel. The experiments were conducted based on response surface methodology (RSM) and sequential approach using central composite design (CCD). Response surface methodology was employed to optimize the set of parameters to ensure a minimum surface roughness. A non-linear second order model best describes the variation of surface roughness with major contribution of ball diameter and number of tool passes. The optimum conditions found by RSM for the deep cold rolling process are, rolling force of 507.7N, ball diameter of 10mm, initial roughness of 4.84μm and 3 number of tool passes.

Item Type: Article
Uncontrolled Keywords: DCR, CCD, Optimization, Response surface methodology, Surface roughness
Subjects: Engineering > MIT Manipal > Mechanical and Manufacturing
Depositing User: MIT Library
Date Deposited: 27 Feb 2013 11:12
Last Modified: 27 Feb 2013 11:12
URI: http://eprints.manipal.edu/id/eprint/78777

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