Machinability Assessment through Experimental Investigation during Hard and Soft Turning of Hardened Steel (original) (raw)
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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.
The International Journal of Advanced Manufacturing Technology, 2014
The hard turning process has been attracting interest in different industrial sectors for finishing operations of hard materials. In this paper, the effects of cutting speed, feed rate, and depth of cut on surface roughness, cutting force, specific cutting force, and power in the hard turning were experimentally investigated. An experimental investigation was carried out using ceramic cutting tools, composed approximately with (70 %) of Al 2 O 3 and (30 %) of TiC, in surface finish operations on cold work tool steel AISI D3 heat-treated to a hardness of 60 HRC. Based on 3 3 full factorial designs, a total of 27 tests were carried out. The range of each parameter is set at three different levels, namely, low, medium, and high. Analysis of variance is used to check the validity of the model. Experimental observations show that higher cutting forces are required for machining harder work material. This cutting force gets affected mostly by feed rate followed by depth of cut. Feed rate is the most influencing factor on surface roughness. Feed rate followed by depth of cut become the most influencing factors on power; especially in case of harder workpiece. Optimum cutting conditions are determined using response surface methodology (RSM) and the desirability function approach. It was found that, the use of lower depth of cut value, higher cutting speed, and by limiting the feed rate to 0.12 and 0.13 mm/rev, while hard turning of AISI D3 hardened steel, respectively, ensures minimum cutting forces and better surface roughness. Higher values of depth of cut are necessary to minimize the specific cutting force.
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.
Mechanics & Industry
The hard turning process has an attracting interest in different industrial sectors for finishing operations of hard materials. However, it still presents disadvantages with respect to process capability and reliability. This paper describes a comparison of surface roughness, specific cutting force and flank wear between mixed ceramic CC650 (Al2O3 (70%) + TiC (30%)) and reinforced ceramic CC670 (Al2O3 (75%) + SiC (25%)) cutting tools when machining in dry hard turning of AISI 4140, treated at 52 HRC using the response surface methodology (RSM). A mathematical prediction model of the machining responses has been developed in terms of cutting speed, feed rate and cutting time parameters. Experimental observations show that the surface roughness obtained with the mixed ceramic insert significantly improved when compared with reinforced ceramic insert with a ratio of 1.44. In the same way, insert CC650 has better performance compared to reinforced ceramic inserts CC670, in terms of the ...
The cutting tool stresses in finish turning of hardened steel with mixed ceramic tool
The International Journal of Advanced Manufacturing Technology, 2015
Precision hard machining is an interesting topic in manufacturing die and mold, automobile parts, and scientific research. While the hard machining has benefit advantages such as short cutting cycle time, process flexibility, and low surface roughness, there are several disadvantages such as high tooling cost, need of rigid machine tool, high cutting stresses, and residual stresses. Especially, tool stresses should be understood and dealt with to achieve successful performance of finish hard turning with ceramic cutting tool. So, the influence of cutting parameters on cutting stresses during dry finish turning of hardened (52 HRC) AISI H13 hot work steel with ceramic tool is investigated in this paper. For this aim, a series finish turning tests were performed, and the cutting forces were measured in tests. After literature procedure about finite element model (FEM), FEM is established to predict cutting stresses in finish turning of hardened AISI H13 steel with Ceramic 650 grade insert. As shown, effect of the cutting parameters on cutting tool stresses in finish turning of AISI H13 steel is obtained. The suggested results are helpful for optimizing the cutting parameters and decreasing the tool failure in finish turning applications of hardened steel.
Journal of Physics: Conference Series, 2019
In the present work, the effects of machining factors and cutting fluid flow conditions on tool wear and surface roughness were studied. Response surface methodology technique with Face centered composite design was employed to minimize the number of experiments. The experiments were performed on a hardened AISI D2 rod using mixed ceramic (Al 2 O 3 /TiC) inserts in turning process. The effect of machining time was found to be the most influential parameter affecting tool wear, followed by cutting speed. However, machining time followed by feed rate were the most significant parameters on surface roughness. Moreover, cutting fluid condition showed substantial contribution towards decreasing tool wear rate and increasing surface finish.
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...
Influence Of Machining Parameter On Cutting Force And Surface Roughness While Turning Alloy Steel
Materials Today: Proceedings, 2018
Alloy steels are preferred for manufacturing of machine parts owing to their physical and mechanical properties. However, these parts require turning operation to be carried out in order to obtain desired quality product. Components can be machined at minimum lead time, with higher machining parameters such as cutting speed, feed/revolution and depth of cut, which leads to increase in cutting force and surface roughness. Thus, the main objective of present research work is to study the influence of machining parameters on cutting force and surface roughness while machining alloy steels following ISO3685 standards. The experimental results revealed that the surface roughness was low at 350m/min cutting speed and 0.15mm/revolution feed. The cutting forces measured around 35% greater while machining HCHCr alloy steel when compared to EN24 grade alloy steel.
Performance of coated and uncoated mixed ceramic tools in hard turning process
Measurement, 2016
The present contribution deals with the study of the effects of cutting speed, feed rate and depth of cut on the performance of machining which traditionally named ''machinability". The focus is made on the effect of the pre-cited cutting parameters on the evolution of surface roughness and cutting force components during hard turning of AISI D3 cold work tool steel with CC6050 and CC650 ceramic inserts. Also, for both ceramics a comparison of their wear evolution with time and its impact on the surface equality was proposed. The planning of experiments was based on Taguchi's L 16 orthogonal array. The analysis of variance (ANOVA), the signal-to-noise ratio and response surface methodology (RSM) were adopted. Consequently, the validity of proposed linear regression model was checked and the most important parameter affecting the surface roughness and cutting force components were determined. Furthermore, in order to determine the levels of the cutting regime that lead to minimum surface roughness and minimum machining force the relationship between cutting factors was analyzed. The results revealed that the surface quality obtained with the coated CC6050 ceramic insert is 1.6 times better than the one obtained with uncoated CC650 ceramic insert. However, the uncoated ceramic insert was useful in reducing the machining force.
2008
The aim of this work is to evaluate cutting forces and surface roughness in hard turning of hot work steel X38CrMoV5-1 [AISI H11].This steel is hardened to 50 HRC, machined by a mixed ceramic tool (insert CC650 of chemical composition 70%Al2O3+30%TiC), free from tungsten on Cr-Mo-V ba-sis, 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.The tests of slide-lathing were carried out accord-ing to the method of planning experiments. The results made it possible to study the influence of cutting variables (feed rate, cutting speed and depth of cut) and flank wear (VB) on cutting forces and surface roughness. Mathemati-cal models were established to express the influence de-gree of each cutting regime element on the studied techno-logical parameters. Thus, the ranges of the best cutting conditions a...