The Development of Surface Roughness Model When Turning Hardened Steel with Ceramic Cutting Tool Using Response Methodology (original) (raw)
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SURFACE ROUGHNESS EVALUATION WHEN MACHINING CARBON STEEL WITH CERAMIC CUTTING TOOLS
Uludağ University Journal of The Faculty of Engineering, 2009
The response surface methodology was adopted to investigate the effects of main cutting parameters such as cutting speed, feed rate, and depth of cut on the surface roughness when turning AISI 1050 carbon steel. Machining tests were carried out with uncoated ceramic (KY1615) and coated ceramic cutting tools (KY4400). Optimal machining conditions for the desired surface finish were determined. The adequacy of the second order developed model was analyzed by using analysis of variance. The experimental results indicated that the feed rate was the dominant factor, followed by the depth of cut. The cutting speed showed the minimal effect on the surface roughness. It could be seen that the KY1615 tool produced a better surface roughness than the KY4400 tool. It was shown that average surface roughness’ of Ra values were about 2.515 μm, 2.984 μm for the KY1615, KY4400 cutting tools, respectively. Furthermore, the analysis of variance for the second-order model indicated that squares terms were significant on the roughness, but interaction terms of cutting parameters were insignificant for both cutting tools.
Surface roughness model in turning hardened hot work steel using mixed ceramic tool
2009
Nomenclature a p -depth of cut, mm; f -feed rate, mm/rev; HRC -Rockwell hardness; R² -coefficient of determination; Ra -arithmetic mean roughness, μm; Rt -total roughness, μm; Rzmean depth of roughness, μm; r ε -tool nose radius, mm; V c -cutting speed, m/min; α -relief angle, degree; γ -rake angle, degree; λ -inclination angle, degree; χ -major cutting edge angle, degree.
Response surface methodology for roughness model in machining high alloyed steel
This experimental study is conducted to determine statistical models of surface roughness criteria in hard turning of high alloyed steel X38CrMoV5-1. This steel is hardened to 50 HRC, machined by a mixed ceramic tool (insert CC650 of chemical composition 70%Al 2 O 3 +30%TiC), free from tungsten on Cr-Mo-V basis, insensitive to temperature changes and having a high wear resistance. It is employed for the manufacture of highly stressed diecasting moulds and inserts with high tool life expectancy, plastic moulds subject to high stress and forging dies.
Measurement, 2013
This research work concerns the elaboration of a surface roughness model in the case of hard turning by exploiting the response surface methodology (RSM). The main input parameters of this model are the cutting parameters such as cutting speed, feed rate, depth of cut and tool vibration in radial and in main cutting force directions. The machined material tested is the 42CrMo4 hardened steel by Al 2 O 3 /TiC mixed ceramic cutting tool under different conditions. The model is able to predict surface roughness of Ra and Rt using an experimental data when machining steels. The combined effects of cutting parameters and tool vibration on surface roughness were investigated while employing the analysis of variance (ANOVA). The quadratic model of RSM associated with response optimization technique and composite desirability was used to find optimum values of cutting parameters and tool vibration with respect to announced objectives which are the prediction of surface roughness. The adequacy of the model was verified when plotting the residuals values. The results indicate that the feed rate is the dominant factor affecting the surface roughness, whereas vibrations on both pre-cited directions have a low effect on it. Moreover, a good agreement was observed between the predicted and the experimental surface roughness. Optimal cutting condition and tool vibrations leading to the minimum surface roughness were highlighted.
Journal of Mechanical Science and Technology, 2012
An experimental investigation was conducted to analyze the effect of cutting parameters (cutting speed, feed rate and depth of cut) and workpiece hardness on surface roughness and cutting force components. The finish hard turning of AISI 52100 steel with coated Al 2 O 3 + TiC mixed ceramic cutting tools was studied. The planning of experiment were based on Taguchi's L 27 orthogonal array. The response table and analysis of variance (ANOVA) have allowed to check the validity of linear regression model and to determine the significant parameters affecting the surface roughness and cutting forces. The statistical analysis reveals that the feed rate, workpiece hardness and cutting speed have significant effects in reducing the surface roughness; whereas the depth of cut, workpiece hardness and feed rate are observed to have a statistically significant impact on the cutting force components than the cutting speed. Consequently, empirical models were developed to correlate the cutting parameters and workpiece hardness with surface roughness and cutting forces. The optimum machining conditions to produce the lowest surface roughness with minimal cutting force components under these experimental conditions were searched using desirability function approach for multiple response factors optimization. Finally, confirmation experiments were performed to verify the pertinence of the developed empirical models.
Influence of Cutting Parameters on Cutting Force and Surface Finish in Turning Operation
Procedia Engineering, 2013
This research reports the significance of influence of speed, feed and depth of cut on cutting force and surface roughness while working with tool made of ceramic with an Al 2 O 3 +TiC matrix (KY1615)and the work material of AISI 1050 steel (hardness of 484 HV). Experiments were conducted using Johnford TC35 Industrial type of CNC lathe. Taguchi method (L27 design with 3 levels and 3 factors) was used for the experiments. Analysis of variance with adjusted approach has been adopted. The results have indicated that it is feed rate which has significant influence both on cutting force as well as surface roughness. Depth of cut has a significant influence on cutting force, but has an insignificant influence on surface roughness. The interaction of feed and depth of cut and the interaction of all the three cutting parameters have significant influence on cutting force, whereas, none of the interaction effects are having significant influence on the surface roughness produced. If power consumption minimization is to be achieved for the best possible surface finish, the most recommended combination of feed rate and depth of cut is also determined.
The paper gives a summary of the experimental research the quality of surface roughness at the final turning of the steel C60 by mixed ceramic cutting tools SH20F from the firm SPK-Feldmuhle. The aim of the research was to determine the best polynomial equation who represent roughness surface in dependence of concentrated tools wearing by comparative analysis various polynomial equations. In the paper is given the original methodology in choice of the polynomial equation. For this experimental researching choosing the third power polynomial, with index nonlinear corelation coefficient R=0,97325.
Study of the Surface Finish When Turning Hardened Steels
Materials, methods & technologies, 2017
This study concentrates on the optimization of process parameters for surface roughness when turning hardened bearing steels using coated ceramic cutting tools and developed the multiple regression models for the surface roughness based on the factors cutting speed, feed rate, depth of cut and cutting fluid. The experimental results indicated that the feed rate was found to be a dominant factor on the surface roughness of Ra and Rz, but the other factors did not indicate the significant effect. In addition, optimal testing parameter for the surface roughness was determined. Average surface roughness obtained was about 0.79 and 4.102 µm for Ra and Rz, respectively, when machining the hardened steels. Furthermore, ANOVA revealed that the feed rate exerted a largest effect on the surface finish at contribution of 64.03%, followed by the depth of cut at 10.47%, respectively.
A MODEL FOR SURFACE ROUGHNESS IN TURNING OF AISI 4140 STEEL USING COATED CARBIDE CUTTING TOOL
The surface roughness model is developed in terms of main cutting parameters such as cutting speed, feed rate, depth of cut and tool nose radius, using a full-factorial design approach. Machining tests were carried out in turning AISI 4140 steels with CVD-coated carbide cutting tools under different conditions. Moreover, analysis of variance is used to examine the impact of machining parameters on surface roughness. It is shown that the feed rate was found to be main influencing factor on the surface roughness, followed by tool's nose radius. However, it decreased with decreasing the feed rate while it increased with decreasing the nose radius. The other parameters remained a stable. Furthermore, the interaction of feed rate/tool's nose radius was found to be statistically significant on the surface finish because their p-values are smaller than 5%.