Modeling and optimization for surface roughness and tool flank wear in hard turning of AISI 4340 steel (35 HRC) using TiSiN-TiAlN nanolaminate coated insert

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
M. Kaladhar
Keyword(s):  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Content Type ◽  
Aisi 4340 Steel ◽  
4340 Steel ◽  
Optimal Set ◽  
Aisi 4340

PurposeThe present study spotlights the single and multicriteria decision-making (MCDM) methods to determine the optimal machining conditions and the predictive modeling for surface roughness (Ra) and cutting tool flank wear (VB) while hard turning of AISI 4340 steel (35 HRC) under dry environment.Design/methodology/approachIn this study, Taguchi L16 design of experiments methodology was chosen. The experiments were performed under dry machining conditions using TiSiN-TiAlN nanolaminate PVD-coated cutting tool on which Taguchi and responses surface methodology (RSM) for single objective optimization and MCDM methods like the multi-objective optimization by ratio analysis (MOORA) were applied to attain optimal set of machining parameters. The predictive models for each response and multiresponse were developed using RSM-based regression analysis. S/N ratios, analysis of variance (ANOVA), Pareto diagram, Tukey's HSD test were carried out on experimental data for profound analysis.FindingsOptimal set of machining parameters were obtained as cutting speed: at 180 m/min., feed rate: 0.05 mm/rev., and depth of cut: 0.15 mm; cutting speed: 145 m/min., feed rate: 0.20 mm/rev. and depth of cut: 0.1 mm for Ra and VB, respectively. ANOVA showed feed rate (96.97%) and cutting speed (58.9%) are dominant factors for Ra and VB, respectively. A remarkable improvement observed in Ra (64.05%) and VB (69.94%) after conducting confirmation tests. The results obtained through the MOORA method showed the optimal set of machining parameters (cutting speed = 180 m/min, feed rate = 0.15 mm/rev and depth of cut = 0.25 mm) for minimizing the Ra and VB.Originality/valueThis work contributes to realistic application for manufacturing industries those dealing with AISI 4340 steel of 35 HRC. The research contribution of present work including the predictive models will provide some useful guidelines in the field of manufacturing, in particular, manufacturing of gear shafts for power transmission, turbine shafts, fasteners, etc.

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.

Development of Tooling Cost Model for High Speed Hard Turning

2011 ◽  
Vol 418-420 ◽  
pp. 1482-1485 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz Al Hazza ◽  
Delvis Agusman ◽  
Agus Geter Edy Sutjipto
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Hard Turning ◽  
Cost Model ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Predictive Regression ◽  
Aisi 4340

The current work presents the development of cost model for tooling during high speed hard turning of AISI 4340 hardened steel using regression analysis. A set of experimental data using ceramic cutting tools, composed approximately of Al2O3 (70%) and TiC (30%) on AISI 4340 heat treated to a hardness of 60 HRC was obtained in the following design boundary: cutting speeds (175-325 m/min), feed rate (0.075-0.125 m/rev), negative rake angle (0 to -12) and depth of cut of (0.1-0.15) mm. The output data is used to develop a new model in predicting the tooling cost using in terms of cutting speed, feed rate, depth of cut and rake angle. Box Behnken Design was used in developing the model. Predictive regression model was found to be capable of good predictions the tooling cost within the boundary design.

scholarly journals VARIATION OF CUTTING PARAMETERS IN THE PROCESS OF TURNING AISI 4340 STEEL ON SURFACE ROUGHNESS

SINERGI ◽  
2019 ◽  
Vol 23 (2) ◽  
pp. 139
Author(s):  
M. Sobron Yamin Lubis ◽  
Erwin Siahaan ◽  
Steven Darmawan ◽  
Adianto Adianto ◽  
Ronald Ronald
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Aisi 4340 Steel ◽  
4340 Steel ◽  
Metal Machining ◽  
Aisi 4340

In the metal machining process, cutting speed and feed rate are cutting parameters that affect the surface quality of the workpiece produced. The use of improper cutting parameters can cause the workpiece surface to be rough, and the cutting toolage to be shorter. This study was conducted to determine the effect of cutting parameters and the use of carbide tools on the surface roughness of metal steel workpieces. The research was carried out using the experimental method of AISI 4340 steel metal workpiece turning using cutting tool coated. Five variations of cutting speed used are: 140 m/min, 150 m/min, 160 m/min, 170 m/min, 180 m/min and three variations in feed rate: 0.25 mm/rev, 0.3 mm/rev, 0.35 mm/rev. After the turning process, the surface roughness of the workpiece is measured using a surface tester. From the results of the study, it was found that the surface roughness value was directly proportional to the feed rate and inversely proportional to the cutting speed. The smallest surface roughness value is 9.56 μm on cutting speed 180 m / min, and feed rate is 0.25 mm/rev. 

scholarly journals Optimization of Dimensional Tolerances and Material Removal Rate in the Orthogonal Turning of AISI 4340 Steel

2021 ◽  
Author(s):  
Chathakudath Sukumaran Sumesh ◽  
Dawood Sheriff Akbar ◽  
Hari Shankar Purandharadass ◽  
Raghunandan J. Chandrasekaran
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 4340 Steel ◽  
4340 Steel ◽  
Aisi 4340

Turning is one of the most used metal removal operations in the industry. It can remove material faster, giving reasonably good surface quality apart from geometrical requirements. Conformity of geometry is one of the most significant requirements of turned components to perform their intended functions. Apart from dimensional requirements, the important geometrical necessities are Circularity, Straightness, Cylindricity, Perpendicularity, etc. Since they have a direct influence on the functioning of the components, the effect of the cutting parameters on them has greater significance. In this paper experiments are carried out to examine the effect of turning parameters such as cutting speed, feed rate, and depth of cut on responses like; straightness, roundness, surface roughness, and material removal rate during turning of AISI 4340 steel. Analysis of Variance (ANOVA) is performed and the influence of parameters on each response is studied. The optimal values of parameters obtained from the study are further confirmed by conducting experiments.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

Some studies on hard turning of AISI 4340 steel using multilayer coated carbide tool

Measurement ◽  
2012 ◽  
Vol 45 (7) ◽  
pp. 1872-1884 ◽  
Author(s):  
R. Suresh ◽  
S. Basavarajappa ◽  
G.L. Samuel
Keyword(s):  
Hard Turning ◽  
Carbide Tool ◽  
Aisi 4340 Steel ◽  
Coated Carbide Tool ◽  
4340 Steel ◽  
Coated Carbide ◽  
Aisi 4340
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