scholarly journals Influence of Cutting Speed and Feed Rate on the Wear of an S-Type Mixed Ceramic Tool in Turning of AISI 4140 Hardened Steel

2019 ◽  
Vol 26 (4) ◽  
Keyword(s):  
Feed Rate ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Ceramic Tool ◽  
Aisi 4140 ◽  
Mixed Ceramic

scholarly journals Analysis and Optimization of Machining Hardened Steel AISI 4140 with Self-Propelled Rotary Tools

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6106
Author(s):  
Waleed Ahmed ◽  
Hussien Hegab ◽  
Atef Mohany ◽  
Hossam Kishawy
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Inclination Angle ◽  
Feed Rate ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Hardened Steel ◽  
Machining Process ◽  
Aisi 4140 ◽  
Steel Aisi

It is necessary to improve the machinability of difficult-to-cut materials such as hardened steel, nickel-based alloys, and titanium alloys as these materials offer superior properties such as chemical stability, corrosion resistance, and high strength to weight ratio, making them indispensable for many applications. Machining with self-propelled rotary tools (SPRT) is considered one of the promising techniques used to provide proper tool life even under dry conditions. In this work, an attempt has been performed to analyze, model, and optimize the machining process of AISI 4140 hardened steel using self-propelled rotary tools. Experimental analysis has been offered to (a) compare the fixed and rotary tools performance and (b) study the effect of the inclination angle on the surface quality and tool wear. Moreover, the current study implemented some artificial intelligence-based approaches (i.e., genetic programming and NSGA-II) to model and optimize the machining process of AISI 4140 hardened steel with self-propelled rotary tools. The feed rate, cutting velocity, and inclination angle were the selected design variables, while the tool wear, surface roughness, and material removal rate (MRR) were the studied outputs. The optimal surface roughness was obtained at a cutting speed of 240 m/min, an inclination angle of 20°, and a feed rate of 0.1 mm/rev. In addition, the minimum flank tool wear was observed at a cutting speed of 70 m/min, an inclination angle of 10°, and a feed rate of 0.15 mm/rev. Moreover, different weights have been assigned for the three studied outputs to offer different optimized solutions based on the designer’s interest (equal-weighted, finishing, and productivity scenarios). It should be stated that the findings of the current work offer valuable recommendations to select the optimized cutting conditions when machining hardened steel AISI 4140 within the selected ranges.

Effects of Cutting Speed and Feed Rate on Surface Roughness in Hard Turning of AISI 4140 with Mixed Ceramic Cutting Tool

2018 ◽  
Vol 779 ◽  
pp. 153-158
Author(s):  
Phacharadit Paengchit ◽  
Charnnarong Saikaew
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machined Surface ◽  
Data Set ◽  
Ceramic Cutting Tool ◽  
Aisi 4140 ◽  
Mixed Ceramic

This work investigated the influences of cutting speed and feed rate on surface roughness in hard turning of AISI 4140 chromium molybdenum steel bar using mixed ceramic inserts Al2O3+TiC under dry condition for automotive industry applications. Turning experiments were conducted by varying cutting speed ranging from 150 to 220 m/min and feed rate ranging from 0.06 to 1 mm/rev. General factorial design was used to analyze the data set of surface roughness and determine statistically significant process factors based on analysis of variance results. The results showed that average surface roughness was significantly affected by feed rate and interaction between cutting speed and feed rate at the level of significance of 0.05. An optimal operating condition for hard turning of AISI 4140 with the ceramic cutting tool that produced a minimum machined surface roughness was obtained at cutting speed of 220 m/min and 0.06 mm/rev.

scholarly journals Relationship between surface roughness and chip morphology when turning hardened steel

2020 ◽  
Vol 26 (3) ◽  
pp. 92-98
Author(s):  
Youcef Abidi
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Ceramic Tool ◽  
Machined Surface ◽  
Aisi 1045 ◽  
Steel Aisi ◽  
Mixed Ceramic

AbstractHard machining is a process which has become highly recommended in manufacturing industry to replace grinding and perform production. The important technological parameters that determine this process are tool wear, machined surface roughness, cutting force and morphology of the removed chip. In this work, an attempt has been made to analyse the morphology and form of chip removed during turning of hardened steel AISI 1045 (40HRC) with mixed ceramic tool type CC650. Using a Taguchi plan L9, whose factors are cutting speed and feed rate with three levels for each. Macroscopic and microscopic results of chip morphology were correlated with these two cutting parameters additional to surface roughness. Sufficient experimental results were obtained using the mixed ceramic tool when turning of hardened steel AISI 1045 (40HRC) at high cutting speeds. Roughness of machined surface confirmed that it is influenced by feed rate. Chips show a sawtooth shape for all combinations of the experimental plan used. The chip form changed with cutting parameters variation and given an important indicator of suraface quality for industriel. Having the indicators on the surface quality from simple control of chip without stopping machining give an important advantage in order to maximize production and reduce costs.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

scholarly journals Analysis of the compromise between cutting tool life, productivity and roughness during turning of C45 hardened steel

2021 ◽  
Vol 27 (1) ◽  
pp. 30-35
Author(s):  
Youcef Abidi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Coefficient Of Determination ◽  
Depth Of Cut ◽  
Machining Productivity ◽  
Mixed Ceramic

Abstract Tool wear and surface roughness as performance indexes are considered to be the most important in terms of hardened materials’ machinability. The best combination of cutting parameters which enhances the compromise between tool life, productivity and machined surface quality contribute to benefice on production cost, which makes manufacturing industry interested in it. The aim of this research is to investigate the life of ceramic cutting tool and machining productivity together with surface roughness during turning of hardened steel C45, with focus on the selection of the optimal cutting parameter combination. The experiments are carried out based on uni-factorial planning methodology of cutting speeds and feed rates. The results show that the mixed ceramic tool is suitable for turning hardened steel C45 (40 HRC) and the conclusion is that it performed well in terms of tool life, productivity and surface quality at a combination of cutting speed (200 m/min), feed (0.08 mm/rev) and depth of cut (0.3 mm). Additionally, a tool life model has been proposed which is presented very high coefficient of determination.

Wear mechanisms of coated mixed-ceramic tools during finish hard turning of hot tool die steel

2009 ◽  
Vol 224 (1) ◽  
pp. 183-193 ◽  
Author(s):  
J S Dureja ◽  
V K Gupta ◽  
V S Sharma ◽  
M Dogra
Keyword(s):  
Feed Rate ◽  
Wear Mechanisms ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Protective Layer ◽  
Depth Of Cut ◽  
Work Piece ◽  
Die Steel ◽  
Mixed Ceramic

The present study aims to investigate the wear mechanisms of a TiN-coated mixed ceramic tool prevalent under different machining conditions during hard turning of hot tool die steel. The different wear mechanisms observed are abrasion wear at low cutting speed, low feed rate, and highest work piece hardness; formation of protective layer and built-up edge (BUE) resulting from tribochemical reactions between constituents of tool and work piece material at moderate speed. High temperature accompanied by high cutting speed resulted in the removal of the protective layer and suppressed the BUE formation. Hard carbide particles of work material at a higher feed rate severely gouged the tool flank land. Chipping and brittle fractures were observed at very low and high depth of cut. Adhesion of work piece material followed by plastic deformation and notching was clearly visible at low work piece hardness. The influence of cutting speed, feed rate, depth of cut, and work piece hardness on the progressive tool flank wear, and flank wear rate (VBr-μm/km) in the steady wear region was also analysed.

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