Experimental Investigation and Surface Roughness analysis on Hard Turning of AISI D2 Steel using Polycrystalline Cubic Boron Nitride (PCBN)

Hard turning is an alternative to traditional grinding in the manufacturing industry for hardened ferrous alloy material above 45 HRC. Hard turning has advantages such as lower equipment cost, shorter setup time, fewer process steps, greater part geometry flexibility and elimination of cutting fluid. In this study, the effect of cutting speed and feed rate on surface roughness in hard turning was experimentally investigated. AISI D2 steel workpiece (62 HRC) was machined with Cubic Boron Nitride (CBN) insert under dry machining. A 2k-factorial design with 4 centre points as an initial design of experiment (DOE) and a central composite design (CCD) as augmented design were used in developing the empirical mathematical models. They were employed for analysing the significant machining parameters. The results show that the surface roughness value decreased (smoother) with increasing cutting speed. In contrary, surface roughness value increased significantly when the feed rate increased. Optimum cutting speed and feed rate condition in this experiment was 105 m/min and 0.10 mm/rev respectively with surface roughness value was 0.267 µm. Further investigation revealed that the second order model is a valid surface roughness model, while the linear model cannot be used as a predicted model due to its lack of fit significance.

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Experimental Investigation and Surface roughness Analysis on Hard turning of AISI D2 Steel using Coated Carbide Insert

Procedia Engineering ◽

10.1016/j.proeng.2014.12.226 ◽

2014 ◽

Vol 97 ◽

pp. 72-77 ◽

Cited By ~ 19

Author(s):

A. Srithar ◽

K. Palanikumar ◽

B. Durgaprasad

Keyword(s):

Surface Roughness ◽

Experimental Investigation ◽

Hard Turning ◽

Aisi D2 Steel ◽

Roughness Analysis ◽

Aisi D2 ◽

Coated Carbide ◽

D2 Steel ◽

Carbide Insert

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Hard Turning of AISI D2 Steel by Polycrystalline Cubic Boron Nitride (PCBN)

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.766-767.649 ◽

2015 ◽

Vol 766-767 ◽

pp. 649-654

Author(s):

A. Srithar ◽

K. Palanikumar ◽

B. Durgaprasad

Keyword(s):

Boron Nitride ◽

Hard Turning ◽

Cubic Boron Nitride ◽

Machining Process ◽

Depth Of Cut ◽

Machining Parameters ◽

Aisi D2 Steel ◽

Polycrystalline Cubic Boron Nitride ◽

Aisi D2 ◽

D2 Steel

The machining of hard turning is performed on hardened steel in the range of 45 to 68 Rockwell hardness using a variety of tool materials such as Polycrystalline cubic boron nitride (PCBN) , Polycrystalline diamond (PCD) and Cubic boron nitride (CBN). It is an alternative to conventional grinding process is a flexible and effective machining process for hardened metals and hence broadly used in various applications such as dies, moulds, tools, gears, cams, shafts, axles, bearings and forgings. Although the process is performed within small depth of cut and feed rates, estimates to reduce machining time as high as 60 % in hard turning. This paper discusses the importance of hard turning of AISI D2 steel. In this study, Experimental investigations are carried out on conventional lathe using prefixed the cutting conditions. The responses studied in the investigation are cutting forces (Fa, Ft and Fz). The cutting parameters considered for the investigation are cutting speed, feed and depth of cut. The influence of machining parameters on response is studied and presented in detail.

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