Surface Roughness, Machining Force and Flank Wear in Turning of Hardened AISI 4340 Steel with Coated Carbide Insert: Cutting Parameters Effects (original) (raw)
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International journal of automotive engineering, 2013
Turning of hardened steels using a single point cutting tool has replaced the cylindrical grinding now as it offers attractive benefits in terms of lower equipment costs, shorter set up time, fewer process setups, higher material removal rate, better surface quality and elimination of cutting fluids compared to cylindrical grinding. In order to obtain desired surface quality by machining, proper machining parameters selection is essential. This can be achieved by improving quality and productivity in metal cutting industries. The present study is to investigate the effect of machining parameters such as cutting speed, feed and depth of cut on surface roughness during dry turning of hardened AISI 4340 steel with CVD (TiN+TiCN+Al2O3+ZrCN) multilayer coated carbide inserts. A full factorial design of experiment is selected for experimental planning and the analysis of variance (ANOVA) has been employed to analyze the significant machining parameters on surface roughness during turning....
2020
AISI 4340 has been widely used in automobile and aerospace industries due to their adequate mechanical and chemical properties. This paper investigated the effect of cutting parameters such as cutting speed, feed and depth of cut on cutting force and cutting temperature in dry turning of AISI 4340 hardened alloy steel with a multilayer coated carbide tool. The optimization of cutting conditions is highly important that helps the manufacturing technocrats in process planning as the economy of machining operation defines the competitive advantage. The study investigated the optimum cutting parameters that could produce a significant reduction in cutting temperature and cutting forces leading to improve tool life as well as the surface finish of the machined surface in hard turning. Taguchi's L9 orthogonal array was used to design the experiment and analysis of variance (ANOVA) was performed to identify the significant factors affecting the cutting forces and cutting temperatures. The experimental results showed that the feed is the most influencing factor on cutting force and cutting temperature followed by the depth of cut and cutting speed.
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%.
Journal of Engineering Research
The present study investigated the machinability aspects, namely, surface roughness, sound intensity, power consumption, and crater wear, during dry turning of hardened AISI 4140 steel (63 HRC) employing (TiCN/Al2O3/TiN) multilayer-coated carbide inserts under dry cutting condition. The relationship between machining parameters and output parameters was determined using the Taguchi design. The analysis of variance was employed to evaluate the contributions of input parameters on output parameters. The main effect plots illustrated the impacts of cutting speed, feed, and depth of cut on response variables. Results show that the feed was the most dominant factor that affects surface roughness. Increasing the feed value increases the surface roughness, power consumption, and sound intensity. In the other part of this study, the constant values for feed (0.3 mm/rev), depth of cut (0.7 mm), and cutting speed (150 m/min) have been selected to evaluate a tool life that has 0.3 mm crater we...
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.
Production & Manufacturing Research, 2014
The study attempts to investigate tool wear (flank wear) and surface roughness during finish hard turning of AISI D3 steel (58HRC) with coated carbide (TiSiN-TiAlN coated) cutting tool. Taguchi L9 (3) 3 orthogonal array has been applied for experimental design. S/N ratio and ANOVA analyses were performed to identify significant parameters influencing tool wear and surface roughness. The cutting speed and feed were the most significant factors influencing tool wear (flank wear), and feed is the most significant factor influencing surface roughness (Ra). Mathematical models for both response parameters i.e. tool wear and surface roughness were obtained through regression analysis. The confirmation experiments carried out at optimal combination of parameters given by Taguchi's analysis, predicted the response factors with less than 5% error. In addition, Desirability function module in RSM was applied to arrive at the optimal setting of input parameters to minimize tool wear and surface roughness. The optimal solution provided by desirability function optimization was compared with the optimal setting of parameters given by Taguchi analysis. The optimization results provided by both techniques are in close proximity.
Journal of Manufacturing and Materials Processing
The manufacturing industry aims to produce many high quality products efficiently at low cost, thereby motivating companies to use advanced manufacturing technologies. The use of high-speed machining is increasingly widespread; however, it lacks a deep-rooted knowledge base needed to facilitate implementation. In this paper, response surface methodology (RSM) has been applied to determine the optimum cutting conditions leading to minimum flank wear in high-speed dry turning on AISI 1045 steel. The mathematical models in terms of machining parameters were developed for flank wear prediction using RSM on the basis of experimental results. The high speed turning experiments were carried out with two coated carbide and a cermet inserts using AISI 1045 steel as work material at different cutting speeds and machining times. The models selected for optimization were validated through the Pareto principle. Results showed the GC4215 insert to be the most optimal option, because it did not re...
International Journal of Industrial Engineering Computations
The present work deals with some machinability studies on tool wear and surface roughness, in finish hard turning of AISI D2 steel using PCBN, Mixed ceramic and coated carbide inserts. The machining experiments are conducted based on the response surface methodology (RSM). Combined effects of three cutting parameters viz., cutting speed, cutting time and tool hardness on the two performance outputs (i.e. VB and Ra), are explored employing the analysis of variance (ANOVA).The relationship(s) between input variables and the response parameters are determined using a quadratic regression model. The results show that the tool wear was influenced principally by the cutting time and in the second level by the cutting tool hardness. On the other hand, cutting time was the dominant factor affecting workpiece surface roughness followed by cutting speed. Finally, the multiple response optimizations of tool wear and surface roughness were carried out using the desirability function approach (DFA).
Journal of Mechanical Science and Technology, 2011
The present study, aims to investigate, under turning conditions of hardened AISI H11 (X38CrMoV5-1), the effects of cutting parameters on flank wear (VB) and surface roughness (Ra) using CBN tool. The machining experiments are conducted based on the response surface methodology (RSM). Combined effects of three cutting parameters, namely cutting speed, feed rate and cutting time on the two performance outputs (i.e. VB and Ra), are explored employing the analysis of variance (ANOVA). Optimal cutting conditions for each performance level are established and the relationship between the variables and the technological parameters is determined using a quadratic regression model. The results show that the flank wear is influenced principally by the cutting time and in the second level by the cutting speed. Also, it is that indicated that the feed rate is the dominant factor affecting workpiece surface roughness.
In manufacturing industry, beside the dimensional and geometric tolerance of a component, surface quality is most commonly specified requirements. Surface roughness plays an important role in the performance of the component. This paper presents a study of the influence of the cutting parameters on the surface roughness during the turning of AISI1045 steel with TiN coated carbide tool. The design of experiments based on the Taguchi technique. The objective was to optimization of the machining parameters as cutting speed, feed rate and depth of cut for surface roughness. Main effect plots are generated and analyzed to find out the relationship between them. Afterwords a confirmation test were performed to make a comparison between the predicted results and the theoretical results.