No abstract

Previously cubic boron nitride (CBN) and ceramic inserts were used for the dry turning of heat-treated D3 tool steel with cutting speed beyond 200 m/min, suffers from severe tool wear and generation of high temperature at the interface. To overcome these shortcomings, a hybrid ceramic insert that is, Al2O3 + Ti (C,N) with coated (TiN) is used in dry turning of D3 tool steel (heat-treated). Use of the hybrid insert with a lower feed rate (0.04 mm/rev) and a minimum depth of cut (0.4 mm) improves the surface quality of the turning process by significantly reducing the tool wear and cutting forces requirement in a cutting speed range of 165– 175 m/min. Even though ceramic tool inserts have high wear resistance at elevated temperatures but it has limited impact strength. So, ceramics is only recommended for shocks and vibration-free high-speed cutting operations of hardened steel under a dry environment. The novelty of this article is the development of a wear map for the analysis and prediction of tool wear. The Scanning electron microscope studies of wear region elucidate that low tool wear that the predominant modes of wear for low tool wear cutting conditions are delamination and abrasion. Besides for higher tool wear the prevailing wear mode is a combination of abrasion as well as adhesion wear. It is perceived that our proposed methodology outperforms the state-of-the-art methods.

AISI D3 steel is a new kind of hardened tool steel with excellent wear resistance. This hard material receives wide promotion, investigation, and application in the die manufacturing industries. In the machining of AISI D3 steel, tool wear has a close relationship with the presence of different constituent elements in the workpiece material and cutting conditions. This study reports an improved experimental investigation approach to the analysis of effect of cutting speed, feed rate, and depth of cut on cutting forces, surface roughness, tool wear, and chip morphology in high-speed turning of AISI D3 steel using a hybrid TiN-coated Al2O3 + TiCN mixed ceramic insert. The range of each parameter is set at different levels for the analysis purpose. The experimental observations show that the cutting force is predominantly influenced by the feed rate accompanied by the depth of cut. The predominant factor influencing flank wear is the feed rate accompanied by the depth of cut and cutting speed. Feed rate is one of the dominating factors that influences the surface finish characteristics. The characterization of tool wear and chip morphology was performed by a scanning electron microscope supplied with energy-dispersive X-ray spectroscopy pattern. The results demonstrated that the predominant wear mechanism of the multilayered hybrid-coated tool was flank wear, crater wear, adhesion wear, and abrasive wear.

Conventional manufacturing processes such as casting, forming, welding, machining, etc., have been optimized using different improvement techniques in the last few decades. The alterations in these processes have led to more efficient and productive manufacturing practices for the industry. One of these modification techniques is the deployment of ultrasonic vibrations in conventional manufacturing processes. In the last few decades, ultrasonic vibration assistance to manufacturing processes has seen an uprise and was the point of attraction for different research groups. Several improvements by utilizing ultrasonic vibration in manufacturing practices have been reported by the authors in the past. In this article, an attempt has been made to review all the reported techniques for different conventional processes viz. casting, forming, machining, and welding. The article outlines different research findings from the extensive work on ultrasonic vibration assistance showcasing the improved mechanical and morphological properties. The improvisation in the performance parameters viz. friction reduction, stress reduction, tool wear, surface finish, and grain structure has been witnessed by ultrasonic assistance in contrast to simple manufacturing processes. The outcomes have been summarized along with the optimized set of parameters from various studies.