Surface roughness evaluation of various cutting materials in hard turning of AISI H11 (original) (raw)
Related papers
The International Journal of Advanced Manufacturing Technology, 2013
In this study, the effects of cutting speed, feed rate, workpiece hardness and depth of cut on surface roughness and cutting force components in the hard turning were experimentally investigated. AISI H11 steel was hardened to (40; 45 and 50) HRC, machined using cubic boron nitride (CBN 7020 from Sandvik Company) which is essentially made of 57% CBN and 35% TiCN. Four-factor (cutting speed, feed rate, hardness and depth of cut) and three-level fractional experiment designs completed with a statistical analysis of variance (ANOVA) were performed. Mathematical models for surface roughness and cutting force components were developed using the response surface methodology (RSM). Results show that the cutting force components are influenced principally by the depth of cut and workpiece hardness; on the other hand, both feed rate and workpiece hardness have statistical significance on surface roughness. Finally, the ranges for best cutting conditions are proposed for serial industrial production.
Effect of Machining Parameters on Surface Roughness in Hard Turning Process
2015
PROF. JAYESH V. DESAI Asst. Prof. Mechanical Engineering Dept. LDRP-ITR, Gandhinagar Gujarat (India) Abstract: The development of more wear-resistant tool materials such as Polycrystalline Cubic Boron Nitride (PCBN) and ceramics have made hard turning a potential alternative to grinding operations in the finishing of hard materials. The effect of machining parameters has long been an issue in understanding mechanics of turning. Machining parameters has significant influence on chip formation, heat generation, tool wear, surface finish and surface integrity during turning Therefore, an effort has been made in this research to evaluate the effect of machining parameters nose radius, cutting speed and feed rate on surface roughness when turning tool steel H-11 with CBN tool. Machining trials was performed based on full factorial design under dry condition on Lathe in which I have measured surface roughness. The combined effects of the process parameters on performance characteristics a...
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.
Multidiscipline Modeling in Materials and Structures, 2008
This paper presents a study of the development of surface roughness model when turning the mild steel hardened up to 484 HV with mixed alumina ceramic (KY1615) and coated alumina ceramic cutting tools (KY4400). The model was developed in terms of main cutting parameters such as cutting speed, feed rate and depth of cut, using response surface methodology. The established equation indicated that the feed rate affected the surface roughness the most, but other parametres remined stable for arithmetic average height parametre (Ra). However, it decreased with increasing the cutting speed, and with the starting and finishing point of cut for ten point height parametre (Rz). The cutting speed and the depth of cut had a slight effect on surface roughness values of Ra, Rz when using KY4400 cutting tools. Furthermore, the average surface roughness value of Ra was about 0.926 um, 1.089 um for KY1615, KY4400 cutting tools, respectively. The predicted surface roughness was found to be very clos...
2020
This study evaluates the surface roughness and current values using cutting parameters in the turning of AISI H11 being hot work tool steel under dry machining conditions. The selected design factors are the depth of cut, feed rate, cutting speed. A design of experiments was used to carry out this research. The obtained results were analyzed to determine the effects of input parameters on the resultant surface roughness, current using the analysis of variance (ANOVA) and the Response Surface Methodology (RSM). The experimental results showed that increasing feed rate increased the surface roughness, and current values. The most effective cutting parameter on all the output parameters was found to be the feed rate on the surface roughness. Also, the motor current values were influenced by the 38,48% depth of cut, 23,98% cutting speed, 25,52% feed rate, respectively.
Sadhana-academy Proceedings in Engineering Sciences, 2011
This experimental study is conducted to determine statistical models of cutting forces in hard turning of AISI H11 hot work tool steel (∼ 50 HRC). This steel is 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, helicopter rotor blades and forging dies. The workpiece is machined by a mixed ceramic tool (insert CC650 of chemical composition 70%Al 2 O 3 +30%TiC) under dry conditions. Based on 3 3 full factorial design, a total of 27 tests were carried out. The range of each parameter is set at three different levels, namely low, medium and high. Mathematical models were deduced by software Minitab (multiple linear regression and response surface methodology) in order to express the influence degree of the main cutting variables such as cutting speed, feed rate and depth of cut on cutting force components. These models would be helpful in selecting cutting variables for optimization of hard cutting process. The results indicate that the depth of cut is the dominant factor affecting cutting force components. The feed rate influences tangential cutting force more than radial and axial forces. The cutting speed affects radial force more than tangential and axial forces.
Measurement, 2019
Surface roughness of components having hardness above 45 HRC (Rockwell hardness) like bearings, dies, tools etc. draws specific attention during the turning process. Analysis of surface roughness is presented by many researchers based on cutting conditions during hard turning. In this paper, analysis of surface roughness of AISI D2 steel in hard turning with CBN (cubic boron nitride) tools is performed based on variables like cutting speed, feed and nose radius at a constant depth of cut. Variation of feed affects surface roughness most significantly followed by
2019
In this study, influences of cutting parameters in hard turning of hot work tool steel by applying minimum quantity lubrication (MQL) were investigated and optimized by using Taguchi methodology. Firstly, the machinability experiments on hardened AISI H10A hot work tool steel with CBN inserts were performed under the MQL condition. The experiments were carried out by Taguchi ’ s L9 orthogonal array. The machinability of AISI H10A steel were evaluated in terms of average surface roughness (Ra) and main cutting force (Fc). The analysis of variance (ANOVA) was applied to determine the effects of cutting parameters (cutting speed, feed rate and depth of cut) on surface roughness and cutting force. It was observed that surface roughness and cutting force increased with increasing feed rate and depth of cut in machining by applying MQL with uncoated CBN inserts. Depth of cut was determined as the most important parameter on surface roughness with 66.57% PCR while feed rate was determined ...
Investigation of Process Parameters DURING HARD TURNING OF AISI H11 Hardened steel
In this study, the effects of cutting speed, feed rate, work piece hardness and depth of cut on surface roughness and tool tip temperature in the hard turning were experimentally investigated. AISI H11 (X38CrMoV5-1) steel was hardened to (40; 45 and 50) HRC, machined using cubic boron nitride (CBN 7025 from Sandvik Company) which is essentially made of 60% CBN. L27 orthogonal array based Taguchi optimization technique is used to optimize the effect of various cutting parameter for surface roughness and tool tip temperature of H11 work material in turning operation. An orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) are to be employed to analyze the effects and contributions of cutting parameter on the response variables. Attempt was further made to simultaneously optimize the machining parameters using Grey relational analysis. The feed rate is the most significant factor for minimize both surface roughness and tool tip temperature. The surface roughness was measured using surface roughness tester (Mitutoyo surftest-SJ210). Tool tip temperature was measured using Optex Thermo Hunter.
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%.