Surface roughness and cutting forces modeling for optimization of machining condition in finish hard turning of AISI 52100 steel

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).

Section: Introductionmentioning

confidence: 99%

Modelling and analysis of tool wear and surface roughness in hard turning of AISI D2 steel using response surface methodology

Mir¹,

Wàňi²

2018

“…In order to study the performance of coated carbide inserts, ceramic and cubic boron nitride (CBN) tools, recently a various investigation have been carried out. Azizi et al (2012) conducted an experimental investigation to determine the significant parameters affecting the surface roughness and cutting forces, in finish hard turning of AISI 52100 steel, by using the response surface methodology (RSM). They applied an optimization study of machining conditions to produce the lowest surface roughness with minimal cutting force components using desirability function approach for multiple response factors optimization.…”

Section: Introductionmentioning

confidence: 99%

Modeling and multi-objective optimization of surface roughness and productivity in dry turning of AISI 52100 steel using (TiCN-TiN) coating cermet tools

Keblouti¹,

Boulanouar²,

Azizi³

et al. 2017

Self Cite

The present work concerns an experimental study of turning with coated cermet tools with TiCNTiN coating layer of AISI 52100 bearing steel. The main objectives are firstly focused on the effect of cutting parameters and coating material on the performances of cutting tools. Secondly, to perform a Multi-objective optimization for minimizing surface roughness (Ra) and maximizing material removal rate by desirability approach. A mathematical model was developed based on the Response Surface Methodology (RSM). ANOVA method was used to quantify the cutting parameters effects on the machining surface quality and the material removal rate. The results analysis shows that the feed rate has the most effect on the surface quality. The effect of coating layers on the surface quality is also studied. It is observed that a lower surface roughness is obtained when using PVD (TiCN-TiN) coated insert when compared with uncoated tool. The values of root mean square deviation and coefficient of correlation between the theoretical and experimental data are also given in this work where the maximum calculated error is 2.65 %.

“…The influence on surface integrity and cutting forces has been studied and developed a statistical model for cutting forces and surface roughness. Azizi et al (2012) studied the influence of cutting parameters and workpiece hardness on surface roughness and cutting force during turning hardened AISI 52100 steel with coated Al2O3 + TiC mixed ceramic cutting tools. The contributing effect of surface roughness is found to be feed rate, workpiece hardness and cutting speed.…”

Section: Introductionmentioning

confidence: 99%

Statistical regression modeling and machinability study of hardened AISI 52100 steel using cemented carbide insert

Panda¹,

Sahoo²,

Rout³

2017

The present study investigates performance and feasibility of application of low cost cemented carbide insert in dry machining of AISI 52100 steel hardened to (55 ± 1 HRC) which is rarely researched as far as machining of bearing steel is concerned. Machinability studies i.e. flank wear, surface roughness and morphology analysis of chip has been investigated and statistical regression modeling has been developed. The test has been conducted based on Taguchi L16 OA taking machining parameters like cutting speed, feed and depth of cut. It is observed that uncoated cemented carbide insert performs well at some selected runs (Run 1, 5 and 9) which show its feasibility for hard turning applications. The developed serrated saw tooth chip of burnt blue colour adversely affects the surface quality. Adequacy of the developed statistical regression model has been checked using ANOVA analysis (depending on F value, P value and R 2 value) and normal probability plot at 95% confidence level. The results of optimal parametric combinations may be adopted while turning hardened AISI 52100 steel under dry environment with uncoated cemented carbide insert.