scholarly journals Analysis and Optimization of Ceramic Cutting Tool In Hard Turning of EN-31 Using Factorial Design

2012 ◽  
pp. 53-58
Author(s):  
Chetan Darshan ◽  
Lakhvir Singh ◽  
APS Sethi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Analysis Of Variance ◽  
Feed Rate ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Good Surface ◽  
En 31

Manufacturers around the globe persistently looking for the cheapest and quality manufactured machined components to compete in the market. Good surface quality is desired for the proper functioning of the produced parts. The surface quality is influenced by cutting speed, feed rate and depth of cut and many other parameters. In the present study attempt has been made to evaluate the performance of ceramic inserts during hard turning of EN-31 steel. The analysis of variance is applied to study the effect of cutting speed, feed rate and depth of cut on Flank wear and surface roughness. Model is found to be statically significant using regression model, while feed and depth of cut are the factor affecting Flank wear and feed is dominating factors for surface roughness. The analysis of variance was used to analyze the input parameters and there interactions during machining. The developed model predicted response factor at 95% confidence level.

Machinability Investigation of HSLA Steel in Hard Turning with Coated Ceramic Tool: Assessment, Modeling, Optimization and Economic Aspects

2019 ◽  
Vol 18 (04) ◽  
pp. 625-655 ◽  
Author(s):  
Asutosh Panda ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ceramic Tool ◽  
Life Estimation

The present study addresses the machinability investigation in finish dry hard turning of high strength low alloy steel with coated ceramic tool by considering cutting speed, feed and depth of cut as machining parameters. The technological parameters like surface roughness, flank wear, chip morphology and economical feasibility have been considered to investigate the machinability performances. Twenty seven set of trials according to full factorial design of experiments are performed and analysis of variance, multiple regression method, Taguchi method, desirability function approach and finally Gilbert’s approach are subsequently applied for parametric influence study, mathematical modeling, multi-response optimization, tool life estimation and economic analysis. Results indicated that feed and cutting speed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness and tool flank wear is considered. Abrasions, adhesion followed by plastic deformation have been observed to be the principal wear mechanism for tool life estimation and observed tool life for coated ceramic insert is 47[Formula: see text]min under optimum cutting conditions. The total machining cost per part is ensued to be lower ($0.29 only) as a consequence of higher tool life, reduction in downtime and enhancement in savings, which finds economical benefits in hard turning. The current work demonstrates the substitution of conventional, expensive and slow cylindrical grinding process, and proposes the most expensive CBN tool alternative using coated ceramic tools in hard turning process considering techno-economical and ecological aspects.

scholarly journals On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

Materials ◽  
2020 ◽  
Vol 13 (9) ◽  
pp. 2036 ◽  
Author(s):  
Adel T. Abbas ◽  
Magdy M. El Rayes ◽  
Monis Luqman ◽  
Noha Naeim ◽  
Hussien Hegab ◽  
...  
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Steel Alloy ◽  
Aisi 4340 Steel ◽  
Aisi 4340

This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

Hard Turning of Hot Work Steel X38CRMOV5-3: Evaluation of Surface Roughness and Current Values Using Cutting Parameters

2020 ◽  
Author(s):  
Ali Kemal Cakir
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Motor Current ◽  
Design Factors

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.

scholarly journals Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

Materials ◽  
2020 ◽  
Vol 13 (24) ◽  
pp. 5677
Author(s):  
Elshaimaa Abdelnasser ◽  
Azza Barakat ◽  
Samar Elsanabary ◽  
Ahmed Nassef ◽  
Ahmed Elkaseer
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Speed ◽  
Hard Turning ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Conventional Machining

This article presents the results of an experimental investigation into the machinability of Ti6Al4V alloy during hard turning, including both conventional and high-speed machining, using polycrystalline diamond (PCD) inserts. A central composite design of experiment procedure was followed to examine the effects of variable process parameters; feed rate, cutting speed and depth of cut (each at five levels) and their interaction effects on surface roughness and cutting temperature as process responses. The results revealed that cutting temperature increased with increasing cutting speed and decreasing feed rate in both conventional and high-speed machining. It was found that high-speed machining showed an average increase in cutting temperature of 65% compared with conventional machining. Nevertheless, high-speed machining showed better performance in terms of lower surface roughness despite using higher feed rates compared to conventional machining. High-speed machining of Ti6Al4V showed an improvement in surface roughness of 11% compared with conventional machining, with a 207% increase in metal removal rate (MRR) which offered the opportunity to increase productivity. Finally, an inverse relationship was verified between generated cutting temperature and surface roughness. This was attributed mainly to the high cutting temperature generated, softening, and decreasing strength of the material in the vicinity of the cutting zone which in turn enabled smoother machining and reduced surface roughness.

Investigations on the Effect of CNC Dry Hard Turning Process Parameters on Surface Integrity: A Multi-performance Characteristics Optimization

2014 ◽  
Vol 14 (1) ◽  
pp. 23-30 ◽  
Author(s):  
Suha K. Shihab ◽  
Zahid A. Khan ◽  
Aas Mohammad ◽  
Arshad Noor Siddiquee
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Influential Factor ◽  
Depth Of Cut ◽  
Micro Hardness ◽  
Dry Cutting

AbstractThe cutting parameters such as the cutting speed, the feed rate, the depth of cut, etc. are expected to affect the two constituents of surface integrity (SI), i.e., surface roughness and micro-hardness. An attempt has been made in this paper to investigate the effect of the CNC hard turning parameters on the surface roughness average (Ra) and the micro-hardness (μh) of AISI 52100 hard steel under dry cutting conditions. Nine experimental runs based on an orthogonal array of the Taguchi method were performed and grey relational analysis method was subsequently applied to determine an optimal cutting parameter setting. The feed rate was found to be the most influential factor for both the Ra and the μh. Further, the results of the analysis of variance (ANOVA) revealed that the cutting speed is the most significant controlled factor for affecting the SI in the turning operation according to the weighted sum grade of the surface roughness average and micro-hardness.

Wear mechanisms of coated mixed-ceramic tools during finish hard turning of hot tool die steel

2009 ◽  
Vol 224 (1) ◽  
pp. 183-193 ◽  
Author(s):  
J S Dureja ◽  
V K Gupta ◽  
V S Sharma ◽  
M Dogra
Keyword(s):  
Feed Rate ◽  
Wear Mechanisms ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Protective Layer ◽  
Depth Of Cut ◽  
Work Piece ◽  
Die Steel ◽  
Mixed Ceramic

The present study aims to investigate the wear mechanisms of a TiN-coated mixed ceramic tool prevalent under different machining conditions during hard turning of hot tool die steel. The different wear mechanisms observed are abrasion wear at low cutting speed, low feed rate, and highest work piece hardness; formation of protective layer and built-up edge (BUE) resulting from tribochemical reactions between constituents of tool and work piece material at moderate speed. High temperature accompanied by high cutting speed resulted in the removal of the protective layer and suppressed the BUE formation. Hard carbide particles of work material at a higher feed rate severely gouged the tool flank land. Chipping and brittle fractures were observed at very low and high depth of cut. Adhesion of work piece material followed by plastic deformation and notching was clearly visible at low work piece hardness. The influence of cutting speed, feed rate, depth of cut, and work piece hardness on the progressive tool flank wear, and flank wear rate (VBr-μm/km) in the steady wear region was also analysed.

Optimisation of Machining Parameters for Milling Polyetheretherketones (PEEK) Biomaterial

2014 ◽  
Vol 699 ◽  
pp. 198-203 ◽  
Author(s):  
Raja Izamshah Raja Abdullah ◽  
Aaron Yu Long ◽  
Md Ali Mohd Amran ◽  
Mohd Shahir Kasim ◽  
Abu Bakar Mohd Hadzley ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Processing Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dimensional Precision ◽  
Good Surface

Polyetheretherketones (PEEK) has been widely used as biomaterial for trauma, orthopaedic and spinal implants. Component made from Polyetheretherketones generally required additional machining process for finishing which can be a problem especially to attain a good surface roughness and dimensional precision. This research attempts to optimize the machining and processing parameters (cutting speed, feed rate and depth of cut) for effectively machining Polyetheretherketones (PEEK) implant material using carbide cutting tools. Response Surface Methodology (RSM) technique was used to assess the effects of the parameters and their relations towards the surface roughness values. Based on the analysis results, the optimal machining parameters for the minimum surface roughness values were by using cutting speed of 5754 rpm, feed rate of 0.026 mm/tooth and 5.11 mm depth of cut (DOC).

The Effect of Cutting Speed and Feed Rate on Surface Roughness and Tool Wear when Machining Machining D2 Steel

2017 ◽  
Vol 909 ◽  
pp. 80-85 ◽  
Author(s):  
Mohd Rasidi Ibrahim ◽  
Tharmaraj Sreedharan ◽  
Nurul Aisyah Fadhlul Hadi ◽  
Mohammad Sukri Mustapa ◽  
Al Emran Ismail ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Surface Quality ◽  
Feed Rate ◽  
Input Parameter ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
D2 Steel

Machining parameters is a main aspect in performing turning operations using lathe machines. Cutting parameters such as cutting speed, feed rate and depth of cut gives big influence on the dynamic behavior of the machining system. In machining parts, surface quality and tool wear are the most crucial customer requirements. This is because the major indication of surface quality on machined part is the surface roughness and the value of tool wear. Hence, to improve the surface roughness and minimize the forming of tool wear, the optimum feed rate and cutting speed will be determined. The input parameter such as cutting speed, feed rate and depth of cut always influence the tool wear, surface roughness, cutting force, cutting temperature, tool life and dimensional accuracy. The D2 steel was being investigated from the perspective of the effect of cutting speed and feed rate on its surface roughness and tool wear. The results show that cutting speed is the main parameter which affects the surface roughness where the most optimum parameter would be at cutting speed of 173, 231 and 288 m/min with feed rate of 0.15 mm/rev. The tool wear strongly affected by feed rate where at 0.15 mm/rev the tool wear value is the lowest. The combination of high cutting speed and low feed rate was the best parameter to achieve smooth surface roughness.

scholarly journals Surface Quality and Chip Formation in Turning of LM6 Aluminium Alloy and Particulate Reinforced Metal Matrix Composite

2013 ◽  
Vol 773-774 ◽  
pp. 894-901
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Surface Quality ◽  
Chip Formation ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Cutting Condition

Majority of the components of aerospace and automotive vehicles need different machining operations, mainly for the assembly requirements. The components have to present both high dimensional precision and surface quality. This present work is concerned with the effect of cutting parameters (cutting speed, feed rate and depth of cut) on the surface roughness and the chip formation in turning process. The machining results are compared with LM6 aluminium alloy and TiC reinforced metal matrix composite under the same cutting conditions and tool geometry. The cutting condition models designed based on the Design of Experiments Response Surface Methodology. The objective of this research is to obtaining the optimum cutting parameters to get a better surface quality and also the chip formation and furthermore does not hazardous to the worker and the machined products quality. Results shows that Surface roughness values of LM6-TiC composite are higher as compared LM6 alloy at similar cutting condition. With increasing in cutting speed improves the surface quality. The surface quality increases with decrease of the feed rate and the depth of cut. There are difference chip forms for LM6 aluminium alloy and Al-TiC composite for a similar of cutting condition. Generally, chip formations of both materials are acceptable and favourable for the worker as well as the products and the tools.

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