Experimental investigation into machinability of hardened AISI D6 steel using newly developed AlTiSiN coated carbide tools under sustainable finish dry hard turning

Abstract

In the present study, a newly developed AlTiSiN coating material deposited on carbide insert by scalable pulsed power plasma (SPPP) technique is used for machinability investigation of hardened AISI D6 die steel (65HRC) in finish dry turning. Also, the cutting tool is characterized by various diagnostic tests to evaluate the effectiveness of nanocomposite AlTISiN coating material and its cutting performance. A series of machining trials have been performed under varied cutting conditions (feed, depth of cut, speed) to investigate the machinability concerning surface roughness, flank wear, and chip morphology. Further, an approach towards multi-response optimization and predictive modelling for minimization of flank wear and surface roughness have been performed using response surface methodology. Finally, a unique approach has been proposed for economic analysis and sustainability assessment in hard turning. Result shows that the nanostructured AlTiSiN coating developed lower range of tool wear (VB = 0.044–0.076 mm), produced surface finish (Ra) within 0.322–0.905 µm which is approaching the surface quality to that of cylindrical grinding because of minimum friction coefficient, good bonding capability and enhancement in hardness as well as wear resistance of coating material. Statistical analysis reveals that Ra and VB are influenced principally by feed (84.14%) and cutting speed (53.43%), respectively. With the tool life of 34 min, Gilbert's machining economic model calculated the overall machining cost per part of Rs.61.04 in hard turning using coated carbide insert. Chip morphology confirmed the formation of serrated type saw tooth chips. It is established that machining under dry condition provides environment friendliness, techno-economically feasible to improve sustainability.

Turning of hardened AISI H13 steel with recently developed S3P-AlTiSiN coated carbide tool using MWCNT mixed nanofluid under minimum quantity lubrication

“…Besides the above reason, tool wear plays a significant role in chip serration. 64 From the Figure 15, it was noticed the vibration was significantly increased at the highest cutting speed. This might be the primary reason for getting more wear on the insert’s flank surface resulting prominent chip serration at higher speed range.…”

“…The coating was accomplished by Oerlikon Balzers, the detailed procedure of coating deposition has been stated in the published article. 64 Cutting inserts of different nose radii having ISO specification CNMG 1204 3 3 are fastened into a tool insert holder (ISO standard: PCLNL2020K12) with tool approach angle of 95°, relief angle of 6°, tip angle of 80°, and negative rake angle of 6°. Figure 1(a) illustrates the surface morphology of coated carbide tool which revealed that AlTiSiN coating deposited by S3P method exhibited a highly dense droplet free ultra-thin film and improved surface finish of coating layer due to grain refinement of coating.…”

“…Although scanty researchers 51,63 have reported machinability aspects of AISI H13 steel with costly CBN and ceramic cutting tools for the reason of longer tool life. There is insufficient information in the available literatures, 27,64 that has reported the cutting performance of recently developed low cost S3P-AlTiSiN coated carbide tool in hard turning, which opens up worthy research from the techno-economical prospective for industrial sector. Moreover, no literature is yet available that has analyzed the surface quality of machined part, tool vibration, as well as the cost assessment and morphological study of produced chips in hard turning under nanofluid-MQL.…”

Investigation on the Performance of Coated Carbide Tool during Dry Turning of AISI 4340 Alloy Steel

“…The maximum flank wear was 60.09 µm. The presence of deep plowing grooves and edges on the flank and crater surface indicates the abrasion mode of wear of the insert [ 21 ]. Chip particles also adhered to the flank and crater surface which causes nose wear due to the welding of chips; and (ii) Figure 8 b that maximum crater wear of 44.11 µm was found by SEM.…”

“…Results revealed that: (a) 17% reduction in cutting force using the CVD tool and 13% reduction in cutting force using the PVD insert, and (b) use of MQL reduces work tool interface temperature by 5.7% by CVD tool and 6.7% by PVD respectively. While performing experimental trials of a turning operation on hardened steel, Das et al [ 20 , 21 ] concluded that the rate of feed followed by cutting speed was the influential variable for achieving the high surface finish. When the doc and cutting speed increased it resulted in higher flank wear.…”