The Effect of Cutting Parameters on Surface Integrity in Hard Turning

2011 ◽  
Vol 110-116 ◽  
pp. 751-757 ◽  
Author(s):  
Sanjeev Saini ◽  
Inderpreet Singh Ahuja ◽  
Vishal S. Sharma
Keyword(s):  
Surface Quality ◽  
Surface Integrity ◽  
Hard Turning ◽  
Lower Cost ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Part Quality ◽  
The World

Manufacturers around the world constantly strive for lower cost solutions in order to maintain their competitiveness on machined components and manufactured goods. Globally, part quality has been found to be at acceptable levels and it continues to improve, while the pressure for part piece cost is enormous and is constantly being influenced downward by competition and buyer strategies. In machining processes, it is necessary to attain the desired surface quality in order to produce parts providing the required functioning. The surface quality is influenced by various cutting parameters (cutting speed, feed, depth of cut) and sometimes some other parameters. The objective of this paper is to review the effect of cutting parameters on surface integrity (surface roughness and residual stress) in hard turning.

RSM Based Investigations on the Effects of Cutting Parameters on Surface Integrity during Cryogenic Hard Turning of AISI 52100

2015 ◽  
Vol 15 (3) ◽  
pp. 309-318 ◽  
Author(s):  
Suha K. Shihab ◽  
Zahid A. Khan ◽  
Arshad Noor Siddiquee
Keyword(s):  
Surface Integrity ◽  
Feed Rate ◽  
Hard Turning ◽  
Desirability Function ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Aisi 52100 ◽  
Model Equations

AbstractEffect of cryogenic hard turning parameters (cutting speed, feed rate, and depth of cut) on surface roughness (Ra) and micro-hardness (µH) that constitute surface integrity (SI) of the machined surface of alloy steel AISI 52100 is investigated. Multilayer hard surface coated (TiN/TiCN/Al2O3/TiN) insert on CNC lathe is used for turning under different cutting parameters settings. RSM based Central composite design (CCD) of experiment is used to collect data for Ra and µH. Validity of assumptions related to the collected data is checked through several diagnostic tests. The analysis of variance (ANOVA) is used to determine main and interaction effects. Relationship between the variables is established using quadratic regression model. Both Ra and µH are influenced principally by the cutting speed and the feed rate. Model equations are found to predict accurate values of Ra and µH. Finally, desirability function approach for multiple response optimization is used to produce optimum SI.

Investigations on the Effect of CNC Dry Hard Turning Process Parameters on Surface Integrity: A Multi-performance Characteristics Optimization

2014 ◽  
Vol 14 (1) ◽  
pp. 23-30 ◽  
Author(s):  
Suha K. Shihab ◽  
Zahid A. Khan ◽  
Aas Mohammad ◽  
Arshad Noor Siddiquee
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Influential Factor ◽  
Depth Of Cut ◽  
Micro Hardness ◽  
Dry Cutting

AbstractThe cutting parameters such as the cutting speed, the feed rate, the depth of cut, etc. are expected to affect the two constituents of surface integrity (SI), i.e., surface roughness and micro-hardness. An attempt has been made in this paper to investigate the effect of the CNC hard turning parameters on the surface roughness average (Ra) and the micro-hardness (μh) of AISI 52100 hard steel under dry cutting conditions. Nine experimental runs based on an orthogonal array of the Taguchi method were performed and grey relational analysis method was subsequently applied to determine an optimal cutting parameter setting. The feed rate was found to be the most influential factor for both the Ra and the μh. Further, the results of the analysis of variance (ANOVA) revealed that the cutting speed is the most significant controlled factor for affecting the SI in the turning operation according to the weighted sum grade of the surface roughness average and micro-hardness.

scholarly journals Analysis of tool vibration and surface roughness with tool wear progression in hard turning: An experimental and statistical approach

2020 ◽  
Vol 14 (1) ◽  
pp. 6461-6472
Author(s):  
Nitin Ambhore ◽  
Dinesh Kamble ◽  
Satish Chinchanikar
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Hard Turning ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Tangential Direction ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Tool Vibrations

The machined surface quality and dimensional accuracy obtained during hard turning is prominently gets affected due to tool wear and cutting tool vibrations. With this view, the results of tool wear progression on surface quality and acceleration amplitude is presented while machining AISI 52100 hard steel. Central Composite Rotatable Design (CCRD) is employed to develop experimental plan. The results reported that vibration signals sensed in a tangential direction (Vz) are most sensitive and found higher than the vibrations in the feed direction (Vx) and depth of cut direction (Vy). The acceleration signals in all three directions are observed to increase with the advancement of tool wear and good surface finish is observed as tool wear progresses up-to 0.136mm. The vibration amplitude is discovered high in the range 3 kHz – 10 kHz within selected cutting parameter range (cutting speed 60-180mm/min, feed 0.1-0.5mm/rev, depth of cut 0.1-0.5mm). The investigation is extended for the development of multiple regression models with regression coefficients value 0.9. These models found statically significant and give dependable estimates between a tool vibrations and cutting parameters.

Experimental investigation of the effect of machinability on surface quality and vibration in hard turning of hardened AISI 4140 steels using ceramic cutting tools

2021 ◽  
pp. 095440892110073
Author(s):  
Menderes Kam ◽  
Musa Şeremet
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Turning Process ◽  
Aisi 4140

In industry, hardened steels are used in manufacturing of the products such as machine parts and components. In this context, surface quality and vibration play a significant role for control of cutting parameters and cutting conditions in turning process of hardened steel materials. In this study, it was aimed to investigate the effect of machinability on surface quality (Ra and Rz) and vibration in hard turning of conventional heat treated (CHT) and tempered (T) AISI 4140 (42CrMo4) steel samples using ceramic cutting tools under dry environment. They were selected as cutting parameters; four different cutting speeds (120, 160, 200, and 240 m/min), three different feed rates (0.05, 0.10, and 0.15 mm/rev), and depth of cut (0.2 mm). To make the turning process more efficient and to measure the occurring vibrations, the data were obtained online from the ceramic cutting tool by accelerometers in three axes (x-Ch1, y-Ch2, and z-Ch3 directions). In addition, test results of hardness, tensile, microstructure images, Ra - Rz values, and chip thickness values of the experiment samples were analyzed and compared. With the microstructure obtained after the tempering process applied to the T sample, it was seen that it is more machinable and affects the surface quality - vibration positively. The results showed that the most important cutting parameter affecting vibration and surface quality was found to be the feed rate. The lowest Ra value was found as 0.144 μm at 200 m/min of cutting speed and 0.05 mm/rev of feed rate in the T sample. The lowest vibration amplitude value (Ch3) was measured as 0.0023 gRMS (Root Mean Square) at 120 m/min of cutting speed and 0.05 mm/rev of feed rate. According to the Ra and Rz values found in the literature studies, better surface qualities were obtained in the present study.

scholarly journals Analysis and Optimization of Ceramic Cutting Tool In Hard Turning of EN-31 Using Factorial Design

2012 ◽  
pp. 53-58
Author(s):  
Chetan Darshan ◽  
Lakhvir Singh ◽  
APS Sethi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Analysis Of Variance ◽  
Feed Rate ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Good Surface ◽  
En 31

Manufacturers around the globe persistently looking for the cheapest and quality manufactured machined components to compete in the market. Good surface quality is desired for the proper functioning of the produced parts. The surface quality is influenced by cutting speed, feed rate and depth of cut and many other parameters. In the present study attempt has been made to evaluate the performance of ceramic inserts during hard turning of EN-31 steel. The analysis of variance is applied to study the effect of cutting speed, feed rate and depth of cut on Flank wear and surface roughness. Model is found to be statically significant using regression model, while feed and depth of cut are the factor affecting Flank wear and feed is dominating factors for surface roughness. The analysis of variance was used to analyze the input parameters and there interactions during machining. The developed model predicted response factor at 95% confidence level.

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.

Hard Turning of Hot Work Steel X38CRMOV5-3: Evaluation of Surface Roughness and Current Values Using Cutting Parameters

2020 ◽  
Author(s):  
Ali Kemal Cakir
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Motor Current ◽  
Design Factors

This study evaluates the surface roughness and current values using cutting parameters in the turning of AISI H11 being hot work tool steel under dry machining conditions. The selected design factors are the depth of cut, feed rate, cutting speed. A design of experiments was used to carry out this research. The obtained results were analyzed to determine the effects of input parameters on the resultant surface roughness, current using the analysis of variance (ANOVA) and the Response Surface Methodology (RSM). The experimental results showed that increasing feed rate increased the surface roughness, and current values. The most effective cutting parameter on all the output parameters was found to be the feed rate on the surface roughness. Also, the motor current values were influenced by the 38,48% depth of cut, 23,98% cutting speed, 25,52% feed rate, respectively.

Energy Cost Optimization in High Speed Hard Turning Using Simulated Annealing Algorithm

2015 ◽  
Vol 1115 ◽  
pp. 104-108
Author(s):  
Muataz Hazza F. Al Hazza ◽  
Erry Y.T. Adesta ◽  
Muhammad Hasibul Hasan ◽  
Norhashimah Shaffiar
Keyword(s):  
Simulated Annealing ◽  
Energy Cost ◽  
High Speed ◽  
Hard Turning ◽  
Simulated Annealing Algorithm ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Annealing Algorithm

Selecting the cutting conditions to optimize the economics of machining process as assessed by energy machining cost is essential. The aim of this research is to determine the optimum cutting parameters that minimize the energy cost needed for removing one cubic centimetre of material in High Speed Hard Turning (HSHT) process. To achieve that, a set of experimental machining data to cut hardened steel AISI 4340 was obtained with different ranges of cutting speed, feed rate, depth of cut and negative rake angle using mixed ceramic as a cutting tool. Regression models have been developed by using Box-Behnken design as a design of experiment. Then, the Simulated Annealing Algorithm (SAA) has been used to optimize the cutting parameters. The data collected was statistically modelled. The results show that the range of minimum energy cost to remove one cubic centimetre of material for the three techniques can be achieved in the range of 300 to 308 as a cutting speed, -12 for cutting rake angle, 0.125 as a feed rate and 0.15 as a depth of cut.

scholarly journals Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates

2016 ◽  
Vol 2016 ◽  
pp. 1-9 ◽  
Author(s):  
M. Nurhaniza ◽  
M. K. A. M. Ariffin ◽  
F. Mustapha ◽  
B. T. H. T. Baharudin
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimal Cutting Parameters ◽  
Cnc End Milling

The quality of the machining is measured from surface finished and it is considered as the most important aspect in composite machining. An appropriate and optimum machining parameters setting is crucial during machining operation in order to enhance the surface quality. The objective of this research is to analyze the effect of machining parameters on the surface quality of CFRP-Aluminium in CNC end milling operation with PCD tool. The milling parameters evaluated are spindle speed, feed rate, and depth of cut. The L9 Taguchi orthogonal arrays, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) are employed to analyze the effect of these cutting parameters. The analysis of the results indicates that the optimal cutting parameters combination for good surface finish is high cutting speed, low feed rate, and low depth of cut.

Research on the Surface Roughness of Dry Cutting Different Levels of Austempering Ductile Iron (ADI)

2011 ◽  
Vol 464 ◽  
pp. 496-500
Author(s):  
Xiao Hong Xue ◽  
Xu Hong Guo ◽  
Ting Ting Chen ◽  
Dong Dong Wan ◽  
Qiao Wang
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Isothermal Quenching ◽  
Dry Cutting ◽  
Quenching Temperature

Three cutting tools of different materials (ceramics CC6050, cubic boron nitride CB7025, carbide GC2025) are used for dry turning of 9 groups of ADI which heat-treated under different quenching time and quenching temperature. The surface roughness of ADI workpieces were tested after the finish turning at changed cutting parameters, and the influencing factors of surface quality were analysed. Results showed that the surface roughness values of all 9 groups of ADI workpieces obtained by CC6050 were the lowest and the surface quality was better at lower depth of cut ap and feed rate f with higher cutting speed vc . Meanwhile, the surface roughness was influenced by the isothermal quenching parameters of ADI workpieces significantly.

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