Investigation on Effects of Cutting and Jet Parameters in Turning of AISI 4140 Hardened Alloy Steel
Turning of hardened alloy steel (Hard turning) is a replacement for grinding operation. The heat generation and temperature during hard turning at the cutting zone and due to the friction at tool-chip-workpiece interface are significant parameters which influence chip formation mechanism, tool wear, tool life, surface integrity and hence the machining quality. Cutting fluid performs key role in metal cutting due to its cooling and lubrication action. Flood cooling is a common method of cutting fluid application, in which large quantity of cutting fluid is applied at the cutting zone. Due to environmental, health and safety concerns, the usage of cutting fluid in abundant quantity is being restricted. Most of the researchers have varied the cutting parameters like cutting speed, feed rate and depth of cut to machine different work materials with different cutting tools and studied its effects on cutting force and cutting temperature. It is thus essential to study the combine effect of cutting and jet parameters in machining. This research article focusses on study and optimization of cutting and jet parameters on tool-chip interface temperature and cutting forces during turning hardened alloy steel AISI 4140 steel of 50 HRC using Finite Element Analysis and Taguchi’s Technique. Three levels of cutting speed, feed rate, depth of cut, jet angle and jet velocity are chosen. A suitable L27 Orthogonal array is selected based on Taguchi’s Design of Experiments (DoE) and the output quality characteristics such as tool-chip interface temperature and cutting forces are analyzed by Signal-to-Noise (S/N) ratio. Analysis of Variance is performed to determine the most contributing factor, which shows that the feed and depth of cut are the most prominent contributing parameter followed by cutting speed, jet impingement angle and jet velocity.