Implementing a novel TOPSIS-sine cosine algorithm-based hybrid optimization in machining medium-hardened steel
Abstract Machining medium-hardened steel is particularly challenging because of its high strength and wear resistance, which generate excessive cutting temperatures. The elevated temperature contributes to rapid tool wear and negatively impacts surface quality. Optimizing tool selection, coating com...
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Nature Portfolio
2025-07-01
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| Series: | Scientific Reports |
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| Online Access: | https://doi.org/10.1038/s41598-025-07542-0 |
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| author | Ramanuj Kumar Mohammad Rafighi Oğur İynen M. Prem Kumar Reddy Shrikant Zade Mustafa Özdemir Anish Pandey Ramanpreet Singh |
| author_facet | Ramanuj Kumar Mohammad Rafighi Oğur İynen M. Prem Kumar Reddy Shrikant Zade Mustafa Özdemir Anish Pandey Ramanpreet Singh |
| author_sort | Ramanuj Kumar |
| collection | DOAJ |
| description | Abstract Machining medium-hardened steel is particularly challenging because of its high strength and wear resistance, which generate excessive cutting temperatures. The elevated temperature contributes to rapid tool wear and negatively impacts surface quality. Optimizing tool selection, coating composition, geometry, and process variables is crucial for enhancing machinability. This study applied a novel hybrid TOPSIS-sine cosine algorithm to evaluate the performance of three chemical vapor deposited (CVD)-coated carbide cutting inserts in turning medium-hard AISI 4340 grade steel, considering the depth of cut (a), cutting speed (V), feed (f) and workpiece hardness as input variables. Experimentally obtained machining responses, namely resultant force (Fr), power consumption (Pc), surface roughness (Ra), and sound level (SL), were analyzed and compared to determine the optimum insert type. Insert type-3 (TiCN-Al2O3-TiN) demonstrated superior performance, achieving a 16.68% and 26.74% lower Ra than insert type-1 and type-2, respectively. Moreover, the optimal parameters for the most favorable insert (type-3) are determined as H = 30 HRC, V = 190 m/min, f = 0.1 mm/rev, and a = 0.2 mm. Workpiece hardness (H) emerged as the most influential factor affecting machining outcomes. This research recommended insert type-3 at optimized cutting conditions to improve machinability and sustainability in turning medium-hard AISI 4340 grade steel. |
| format | Article |
| id | doaj-art-6b5c61eb7a3247499d03a7194c54be39 |
| institution | Kabale University |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Nature Portfolio |
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| spelling | doaj-art-6b5c61eb7a3247499d03a7194c54be392025-08-20T04:01:34ZengNature PortfolioScientific Reports2045-23222025-07-0115112010.1038/s41598-025-07542-0Implementing a novel TOPSIS-sine cosine algorithm-based hybrid optimization in machining medium-hardened steelRamanuj Kumar0Mohammad Rafighi1Oğur İynen2M. Prem Kumar Reddy3Shrikant Zade4Mustafa Özdemir5Anish Pandey6Ramanpreet Singh7School of Mechanical Engineering, Kalinga Institute of Industrial Technology (KIIT), Deemed to Be UniversityDepartment of Mechanical Engineering, Başkent UniversityDepartment of Mechanical Engineering, Yozgat Bozok UniversityDepartment of Mechanical Engineering, Aditya UniversityDepartment of Computer Science Engineering, Nagpur Institute of TechnologyDepartment of Machine and Metal Technology, Yozgat Bozok UniversitySchool of Mechanical Engineering, Kalinga Institute of Industrial Technology (KIIT), Deemed to Be UniversityDepartment of Mechanical Engineering, Manipal University JaipurAbstract Machining medium-hardened steel is particularly challenging because of its high strength and wear resistance, which generate excessive cutting temperatures. The elevated temperature contributes to rapid tool wear and negatively impacts surface quality. Optimizing tool selection, coating composition, geometry, and process variables is crucial for enhancing machinability. This study applied a novel hybrid TOPSIS-sine cosine algorithm to evaluate the performance of three chemical vapor deposited (CVD)-coated carbide cutting inserts in turning medium-hard AISI 4340 grade steel, considering the depth of cut (a), cutting speed (V), feed (f) and workpiece hardness as input variables. Experimentally obtained machining responses, namely resultant force (Fr), power consumption (Pc), surface roughness (Ra), and sound level (SL), were analyzed and compared to determine the optimum insert type. Insert type-3 (TiCN-Al2O3-TiN) demonstrated superior performance, achieving a 16.68% and 26.74% lower Ra than insert type-1 and type-2, respectively. Moreover, the optimal parameters for the most favorable insert (type-3) are determined as H = 30 HRC, V = 190 m/min, f = 0.1 mm/rev, and a = 0.2 mm. Workpiece hardness (H) emerged as the most influential factor affecting machining outcomes. This research recommended insert type-3 at optimized cutting conditions to improve machinability and sustainability in turning medium-hard AISI 4340 grade steel.https://doi.org/10.1038/s41598-025-07542-0Coated carbide toolsMedium hardened steelTurningTOPSIS-sine cosine algorithmSurface roughnessCutting forces |
| spellingShingle | Ramanuj Kumar Mohammad Rafighi Oğur İynen M. Prem Kumar Reddy Shrikant Zade Mustafa Özdemir Anish Pandey Ramanpreet Singh Implementing a novel TOPSIS-sine cosine algorithm-based hybrid optimization in machining medium-hardened steel Scientific Reports Coated carbide tools Medium hardened steel Turning TOPSIS-sine cosine algorithm Surface roughness Cutting forces |
| title | Implementing a novel TOPSIS-sine cosine algorithm-based hybrid optimization in machining medium-hardened steel |
| title_full | Implementing a novel TOPSIS-sine cosine algorithm-based hybrid optimization in machining medium-hardened steel |
| title_fullStr | Implementing a novel TOPSIS-sine cosine algorithm-based hybrid optimization in machining medium-hardened steel |
| title_full_unstemmed | Implementing a novel TOPSIS-sine cosine algorithm-based hybrid optimization in machining medium-hardened steel |
| title_short | Implementing a novel TOPSIS-sine cosine algorithm-based hybrid optimization in machining medium-hardened steel |
| title_sort | implementing a novel topsis sine cosine algorithm based hybrid optimization in machining medium hardened steel |
| topic | Coated carbide tools Medium hardened steel Turning TOPSIS-sine cosine algorithm Surface roughness Cutting forces |
| url | https://doi.org/10.1038/s41598-025-07542-0 |
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