Investigation of Process Parameters DURING HARD TURNING OF AISI H11 Hardened steel (original) (raw)

Surface roughness evaluation of various cutting materials in hard turning of AISI H11

International Journal of Industrial Engineering Computations, 2016

This paper describes a comparison of surface roughness between ceramics and cubic boron nitride (CBN7020) cutting tools when machining of AISI H11 hot work steels treated at 50 HRC. Plan is designed according to Taguchi's L18 (21×32) orthogonal array. The response surface methodology (RSM) and analysis of variance (ANOVA) were used to check the validity of multiple linear regression models and to determine the effects, contribution, significance and optimal machine settings of process parameters, namely, cutting speed, feed rate and depth of cut on machining parameters on the Ra and Rt. The results of this research work showed that, the feed rate was found to be a dominant factor on the surface roughness, followed by the cutting speed, lastly the depth of cut. The CBN7020 cutting tool showed the better performance than that of ceramic based cutting tool. In addition, the combination of low feed rate and high cutting speed is necessary for minimizing the surface roughness.

Determination the Effect of Machining Parameters on Roughness in Turning Operation of Din 17210 Steel Using Taguchi Technique

Journal of Production Engineering, 2017

In this research work an attempt has been made to try to investigate the effects of cutting parameters such as feed rate cutting speed and depth of cut on surface roughness in turning operation of 16MnCr5 steel, is a case hardening steel with by the support of Taguchi technique. An orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) were used to determine the effects and contributions of cutting speed, feed rate and depth of cut on the response variable. Turning operations were carried out by Tungsten carbide coated cutting tool inserts. The experiments were conducted at three different cutting speeds (400, 600 and 800 rpm) with three different feed rates (0.06, 0.12 and 0.18 mm/rev) and a constant depth of cut (0.5, 1.0 and 1.5 mm). The cutting parameters are optimized using signal to noise ratio and the analysis of variance.obtained result data revelled that depth of cut has most significant effect over surface roughness followed by cutting speed while feed rate has lowest effect.

Optimization of Cutting Parameters in Hard Turning of AISI H10A Steel under Minimum Quantity Lubrication

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 ...

Statistical and Experimental Investigation of Hardened AISI H11 Steel in CNC Turning with Alternative Measurement Methods

Advances in Materials Science and Engineering

In recent years, hard turning, an alternative to grinding, which provides low cost and good surface quality, has become an attractive method to the manufacturers. In this experimental study, AISI H11 hot work tool steel that has been hardened up to 50 HRC was subjected to hard turning tests with coated carbide tooling. The analyses were carried out by applying response surface methodology with the analysis of variance method. A total of 27 experiments were modeled utilizing 3 3 full factorial design and were carried out using a CNC lathe. The effects of the cutting parameters on surface roughness, energy consumption, electric current value, and sound intensity level were investigated. Optimum cutting parameters and levels were determined according to these optimum values. The relationship between cutting parameters and output variables was analyzed with two-dimensional and three-dimensional graphics. The results show that while the most effective parameter on the surface roughness w...

The Effect of Tool Construction and Cutting Parameters on Surface Roughness and Vibration in Turning of AISI 1045 Steel Using Taguchi Method

This paper presents an experimental investigation focused on identifying the effects of cutting conditions and tool construction on the surface roughness and natural frequency in turning of AISI1045 steel. Machining experiments were carried out at the lathe using carbide cutting insert coated with TiC and two forms of cutting tools made of AISI 5140 steel. Three levels for spindle speed, depth of cut, feed rate and tool overhang were chosen as cutting variables. The Taguchi method L 9 orthogonal array was applied to design of experiment. By the help of signal-to-noise ratio and analysis of variance, it was concluded that spindle speed has the significant effect on the surface roughness, while tool overhang is the dominant factor affecting natural frequency for both cutting tools. In addition, the optimum cutting conditions for surface roughness and natural frequency were found at different levels. Finally, confirmation experiments were conducted to verify the effectiveness and efficiency of the Taguchi method in optimizing the cutting parameters for surface roughness and natural frequency.

Turning Parameter Optimization for Surface Roughness Of AISI 4140 Alloy Steel By Taguchi Method

In this research work machining of the AISI 4140 Alloy steel with the help of coated carbide insert of TNMG 432 PD M400 C7 CVD Al 2 O 3 is performed. Analysis of the surface roughness is done experimentally with specific input values of feed, depth of cut and speed and gradually the optimal condition is found out. A relation between the inputs and the output is determined and thereafter, the analysis is done how the inputs affected the output. First using the full factorial composite design a layout of the experiment is made after which it is conducted. With the help of ANOVA (Analysis of Variance), the most effective or the optimal parameters and possible conclusions are made at the end.

Optimization of Turning Parameters Using Taguchi Technique for MRR and Surface Roughness of Hardened AISI 52100 Steel

In this paper, Taguchi technique is used to find optimum process parameters for turning of hardened AISI 52100 steel under dry cutting conditions. A L9 orthogonal array, signal-to-noise(S/N) ratio and analysis of variances (ANOVA) are applied with the help of Minitab.v.16.2.0 software to study performance characteristics of Machining parameters namely cutting speed, feed rate and depth of cut with consideration of Material Removal Rate (MRR) and surface roughness. The results obtained from the experiments are changed into signal-to-noise ratio(S/N) ratio and used to optimize the value of MRR and surface roughness. The ANOVA is performed to identify the importance of parameters. The final results of experimental study are presented in this paper. The conclusions arrived at are significantly discussed at the end.

Parametric design optimization of hard turning of AISI 4340 steel (69 HRC)

The International Journal of Advanced Manufacturing Technology, 2015

Continuous research endeavors on hard turning (HT), both on machine tools and cutting tools, have made the previously reported daunting limits easily attainable in the modern scenario. This presents an opportunity for a systematic investigation on finding the current attainable limits of hard turning using a CNC turret lathe. Accordingly, this study aims to contribute to the existing literature by providing the latest experimental results of hard turning of AISI 4340 steel (69 HRC) using a CBN cutting tool. An orthogonal array was developed using a set of judiciously chosen cutting parameters. Subsequently, the longitudinal turning trials were carried out in accordance with a welldesigned full factorial-based Taguchi matrix. The speculation indeed proved correct as a mirror finished optical quality machined surface (an average surface roughness value of 45 nm) was achieved by the conventional cutting method. Furthermore, Signal-to-noise (S/N) ratio analysis, Analysis of variance (ANOVA), and Multiple regression analysis were carried out on the experimental datasets to assert the dominance of each machining variable in dictating the machined surface roughness and to optimize the machining parameters. One of the key findings was that when feed rate during hard turning approaches very low (about 0.02mm/rev), it could alone be most significant (99.16%) parameter in influencing the machined surface roughness (Ra). This has, however also been shown that low feed rate results in high tool wear, so the selection of machining parameters for carrying out hard turning must be governed by a trade-off between the cost and quality considerations.

Optimization of Process Parameters of Surface Roughness and Material Removal Rate in Orthogonal Turning of AISI 1045 Carbon Steel Using Taguchi Technique

2021

In today's manufacturing market, quality and productivity play significant role. This study is aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality and as well as productivity. This study investigates the effects of various parameters such as depth of cut, speed and feed on the material removal rate and surface roughness in a HMT (Hindustan Machine Tools) LB25 Lathe Machine. A plan of experiments based on Taguchi's technique has been used to acquire the data. An orthogonal array, the signal to noise (S/N) ratio and the analysis of variance (ANOVA) were employed to investigate the cutting characteristics of 1045 carbon steel using tungsten coated carbide cutting tool. The effectiveness of the predicted values with the experimental values in the analysis was carried out by confirmation tests. The analysis of results shows that the combination of process parameters for minimum surface roughness is obtained at 330 rpm spindle speed, 0.2 mm/rev feed and 0.6mm depth of cut for minimum surface roughness. It is observed that feed rate plays an important role in minimizing surface roughness. For maximum material removal rate, the optimum values are spindle speed of 630 rpm, feed rate of 0.4 mm/ rev and depth of cut of 1.0 mm. Finally, the relationship between cutting parameters and responses were developed by using the Minitab 18.1 software and regression equations were developed.

Investigation of the Effect of Cutting Parameters on Surface Roughness in Dry Turning of Hardened Steel Using the Taguchi Method

2023

In this experimental work, focuses on the investigation of the effect of cutting parameters on surface Roughness and to minimize surface roughness. A CNC lathe machine has conducted the experiments. Dry turning tests are carried out on hardened steel with coated carbide cutting tools. This study sought to give systematic and trustworthy techniques for manufacturers and engineers to efficiently optimize machining parameters, tool selection, and process conditions by using Taguchi Design Optimization. The experiments revealed that the most favorable combination of cutting parameters, which resulted in a minimum surface roughness of 2.6 µm, corresponded to a cutting speed (V) of 120 m/min, a feed rate (F) of 0.2 mm/rev, and a depth of cut (D) of 0.08 mm, yielding an S/N ratio of-8.29947. The utilization of coated tools has been identified as beneficial for enhancing the machining of hard materials when employing higher speeds and reduced feed rates. The findings from this research reveal that the feed rate plays a paramount role in influencing both Ra and Rz. Furthermore, it is noteworthy that the interplay between two factors, namely the feed rate and cutting speed, as well as the depth of cut and cutting speed, exerts notable effects.