Effect of Machining Parameters on Tool Wear and Nodal Temperature in Hard Turning of AISI D3 Steel

Varaprasad Bhemuni^1*, Srinivasa Rao Chelamalasetti², Siva Prasad Kondapalli³

¹GVP School of Engineering (Technical Campus), Rushikonda, Visakhapatnam, India.
²Mechanical Engineering Department, Andhra University, College of Engineering (A), Visakhapatnam, India.
³Mechanical Engineering Department, Anil Neerukonda Institute of Technology & Sciences, Visakhapatnam, India.

DOI: 10.4236/oalib.1100627                

Abstract

Present day metal cutting industry has to meet the challenges of productivity and the quality of the machined parts during the turning processes economically. In the present work, an attempt has been made to develop a model and predict the tool wear and nodal temperature of hard turned AISI D3 hardened steel using Response Surface Methodology (RSM). The combined effects of cutting speed, feed rate and depth of cut are investigated using contour plots. RSM based Central Composite Design (CCD) is applied as an experimental design. Al₂O₃/TiC mixed ceramic tool with a corner radius of 0.8 mm is employed to accomplish 20 tests with six centre points. The adequacy of the developed models is checked using Analysis of Variance (ANOVA). Main and interaction plots are drawn to study the effect of process parameters on output responses.

Keywords

Hard Turning, Tool Flank Wear, Nodal Temperature, AISI D3, RSM

Conflicts of Interest

The authors declare no conflicts of interest.

References

[1]	Özel, T. and Karpat, Y. (2005) Predictive Modeling of Surfsce Roughness and Tool Wear in Hard Turning Using Regression and Neural Networks. International Journal of Machine Tools and Manufacture, 45, 467-479. http://dx.doi.org/10.1016/j.ijmachtools.2004.09.007
[2]	Mohammadi, A. and Zarepour, H. (2008) Statistical Analysis of Hard Turning Of AISI 4340 Steel on Surface Finish and Cutting Region Temperature. M0048010, Bahrain, Manama, AMPT 2008.
[3]	Kountanya, R.K. (2008) Optimizing PCBN Cutting Tool Performance in Hard Turning. Proceeding of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 222, 969-980.
[4]	Hamdan, A., Sarhan Ahmed, A.D. and Hamdi M.A. (2012) Optimization Method of the Machining Parameters in High Speed Machining of Stainless Steel Using Coated Carbide Tool for Best Surface Finish. The International Journal of Advanced Manufacturing Technology, 58, 81-91. http://dx.doi.org/10.1007/s00170-011-3392-5
[5]	Shaw, M.C. (2005) Metal Cutting Principles. Oxford University Press, New York.
[6]	Khidhir, B.A. and Mohamed, B. (2011) Analyzing the Effect of Cutting Parameters on Surface Roughness and Tool Wear When Machining Nickel Based Hastelloy-276. IOP Conference Series: Materials Science and Engineering, 17, 1-10.
[7]	Singh, H., Khanna, R. and Garg, M.P. (2011) Effect of Cutting Parameters on MRR and Surface Roughness in Turning EN-8. International Journal of Current Engineering and Technology, 1, 100-104.
[8]	Jaharah, A.G., RodziMohd Nor, A.M., Rahman, A.A., Rahman Mohd Nizam, A. and Hassan, C.H.C. (2009) Machinability of FCD 500 Ductile Cast Iron Using Coated Carbide Tool in Dry Machining Condition. International Journal of Mechanical and Materials Engineering, 4, 279-284.
[9]	Lalwani, D.I., Mehta, N.K. and Jain P.K. (2008) Experimental Investigations of Cutting Parameters Influence on Cutting Forces and Surface Roughness in Finish Hard Turning of MDN250 Steel. Journal of Materials Processing Technology, 206, 167-179. http://dx.doi.org/10.1016/j.jmatprotec.2007.12.018
[10]	Kaladhar, M., Subbaiah, K.V. and Rao, Ch.S. (2012) Parametric Optimization during Machining of AISI 304 Austenitic Stainless Steel Using CVD Coated DURATOMICTM Cutting Insert. International Journal of Industrial Engineering Computations, 3, 577-586.
[11]	Montgomery, D.C. (1997) Design and Analysis of Experiments. John Wiley & Sons, New York.
[12]	Davim, J.P. and Figueira, L. (2007) Machinability Evaluation in Hard Turning of Cold Work Tool Steel (D2) with Ceramic Tools Using Statistical Techniques. Journal of Materials and Design, 28, 1186-1191. http://dx.doi.org/10.1016/j.matdes.2006.01.011
[13]	Aggarwal, A., Singh, H., Kumar, P. and Singh, M. (2008) Optimizing Power Consumption for CNC Turned Parts Using Response Surface Methodology and Taguchi’s Technique—A Comparative Analysis. Journal of Material Processing Technology, 200, 373-384. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.041
[14]	Yanda, H., Ghani, J.A., Rodzi, M.N.A.M., Othman, K. and Haron, C.H.C. (2010) Optimization of Material Removal rate, Surface Roughness and Tool Life on Conventional Dry Turning of FCD700. International Journal of Mechanical and Materials Engineering, 5, 182-190.
[15]	Sahin, Y. (2009) Comparison of Tool Life between Ceramic and Cubic Boron Nitride (CBN) Cutting Tools When Machining Hardened Steels. Journal of Materials Processing Technology, 209, 3478-3489. http://dx.doi.org/10.1016/j.jmatprotec.2008.08.016
[16]	SuhailAdeel, H., Ismail, N., Wong, S.V. and Jalil, N.A. (2010) Optimization of Cutting Parameters Based on Surface Roughness and Assistance of Nodal Temperature in Turning Process. American Journal of Engineering and Applied Sciences, l3, 102-108. http://dx.doi.org/10.3844/ajeassp.2010.102.108
[17]	Bhattacharya, A., Das, S., Majumder, P. and Batish, A. (2009) Estimating the Effect of Cutting Parameters on Surface Finish and Power Consumption during High Speed Machining of AISI 1045 Steel Using Taguchi Design and ANOVA. Production Engineering, Research and Development, 3, 31-40. http://dx.doi.org/10.1007/s11740-008-0132-2
[18]	Zou, B., Chen, M. and Li, S. (2011) Study on Finish-Turning of NiCr20TiAl Nickel-Based Alloy Using Al2O3/TiN-coated Carbide Tools. International Journal of Advanced Manufacturing Technology, 53, 81-92. http://dx.doi.org/10.1007/s00170-010-2823-z
[19]	Prasad, K.S., Rao, C.S. and Rao, D.N. (2012) Application of Design of Experiments to Plasma Arc Welding Process: A Review. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 34, 75-81.