Abstract
Continuous research endeavors on hard turning (HT), both on machine tools and cutting tools, have made the previously reported daunting limits easily attainable in the modern scenario. This presents an opportunity for a systematic investigation on finding the current attainable limits of hard turning using a CNC turret lathe. Accordingly, this study aims to contribute to the existing literature by providing the latest experimental results of hard turning of AISI 4340 steel (69 HRC) using a CBN cutting tool. An orthogonal array was implemented using a set of judiciously chosen cutting parameters. Subsequently, the longitudinal turning trials were carried out in accordance with a well-designed full factorial-based Taguchi matrix. The speculation indeed proved correct as a mirror finished optical quality machined surface (an average surface roughness value of 45 nm) was achieved by the conventional cutting method using a CBN cutting tool. Furthermore, signal to noise (S/N) ratio analysis, analysis of variance (ANOVA), and multiple regression analysis were carried out on the experimental datasets to assert the dominance of each machining variable in dictating the machined surface roughness and to optimize the machining parameters. One of the key findings was that when feed rate during hard turning approaches very low (about 0.02 mm/rev), it could alone be most significant (99.16 %) parameter in influencing the machined surface roughness (Ra). This has, however, also been shown that low feed rate results in high tool wear; so, the selection of machining parameters for carrying out hard turning must be governed by a trade-off between the cost and quality considerations.
Similar content being viewed by others
References
Tönshoff HK, Arendt C, Amor RB (2000) Cutting of Hardened Steel. CIRP Ann Manuf Technol 49(2):547–566
Grzesik W (2011) Mechanics of Cutting and Chip Formation. In: Davim JP (ed) Machining of Hard Materials. Springer, London, pp 87–114
Rashid WB et al (2013) The development of a surface defect machining method for hard turning processes. Wear 302(1–2):1124–1135
Bartarya G, SK (2013) Choudhury, Influence of machining parameters on forces and surface roughness during finish hard turning of EN 31 steel. Proc Inst Mech Eng B J Eng Manuf: p. 0954405413500492
Grzesik W, J Rech, K Żak (2015) Characterization of surface textures generated on hardened steel parts in high-precision machining operations. Int J Adv Manuf Technol: p. 1–8
Nakai TN, S Tomita, K Goto (1991) Hard Turning by PCBN. Soc Manuf Eng, June, 3(2)
Rashid WB et al (2013) An experimental investigation for the improvement of attainable surface roughness during hard turning process. Proc Inst Mech Eng B J Eng Manuf 227(2):338–342
Rashid WB et al. (2015) Achieving an optical quality surface finish on hard steels using conventional machining (in review). J Mater Process Technol
Bartarya G, Choudhury SK (2012) State of the art in hard turning. Int J Mach Tools Manuf 53(1):1–14
Ross PJ (1995) Taguchi techniques for quality engineering (2nd ed’95)
Taguchi G, S Konishi (1987) Orthogonal arrays and linear graphs: tools for quality engineering. American Supplier Institute Allen Park, MI
Yang W, Tarng Y (1998) Design optimization of cutting parameters for turning operations based on the Taguchi method. J Mater Process Technol 84(1):122–129
Davim JP (2001) A note on the determination of optimal cutting conditions for surface finish obtained in turning using design of experiments. J Mater Process Technol 116(2):305–308
Davim JP (2003) Design of optimisation of cutting parameters for turning metal matrix composites based on the orthogonal arrays. J Mater Process Technol 132(1):340–344
Lin C (2004) Use of the Taguchi method and grey relational analysis to optimize turning operations with multiple performance characteristics. Mater Manuf Process 19(2):209–220
Manna A, Bhattacharyya B (2004) Investigation for optimal parametric combination for achieving better surface finish during turning of Al/SiC-MMC. Int J Adv Manuf Technol 23(9–10):658–665
Yih-fong T (2006) Parameter design optimisation of computerised numerical control turning tool steels for high dimensional precision and accuracy. Mater Des 27(8):665–675
Kirby ED (2006) A parameter design study in a turning operation using the taguchi method. the Technology Interface/Fall 2006
Cirstoiu CA (2005) Influence of feed rate on surface roughness in turning processes with different tool inserts. University“ Politehnica” of Bucharest Scientific Bulletin, Series D. Mech Eng 67(2):63–70
Feng C-X, Wang X-F (2003) Surface roughness predictive modeling: neural networks versus regression. IIE Trans 35(1):11–27
Özel T, Hsu T-K, Zeren E (2005) Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel. Int J Adv Manuf Technol 25(3–4):262–269
Vernon A, T Özel (2003) Factors affecting surface roughness in finish hard turning. in 17th International Conference on Production Research, Blacksburg, Virginia
Tamizharasan T, Selvaraj T, Haq AN (2006) Analysis of tool wear and surface finish in hard turning. Int J Adv Manuf Technol 28(7–8):671–679
Zhang X, Liu CR, Yao Z (2007) Experimental study and evaluation methodology on hard surface integrity. Int J Adv Manuf Technol 34(1–2):141–148
Özel T, Karpat Y (2005) Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks. Int J Mach Tools Manuf 45(4–5):467–479
Thiele JD, Melkote SN (1999) Effect of cutting edge geometry and workpiece hardness on surface generation in the finish hard turning of AISI 52100 steel. J Mater Process Technol 94(2):216–226
Aslan E, Camuşcu N, Birgören B (2007) Design optimization of cutting parameters when turning hardened AISI 4140 steel (63 HRC) with Al < sub > 2</sub > O < sub > 3</sub > + TiCN mixed ceramic tool. Mater Des 28(5):1618–1622
Davim JP, Figueira L (2007) Machinability evaluation in hard turning of cold work tool steel (D2) with ceramic tools using statistical techniques. Mater Des 28(4):1186–1191
Chou YK, Evans CJ, Barash MM (2003) Experimental investigation on cubic boron nitride turning of hardened AISI 52100 steel. J Mater Process Technol 134(1):1–9
Xueping Z, Erwei G, Richard Liu C (2009) Optimization of process parameter of residual stresses for hard turned surfaces. J Mater Process Technol 209(9):4286–4291
Bouacha K et al (2010) Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool. Int J Refract Met Hard Mater 28(3):349–361
Asiltürk I, Akkuş H (2011) Determining the effect of cutting parameters on surface roughness in hard turning using the Taguchi method. Measurement 44(9):1697–1704
Agrawal A et al (2015) Prediction of surface roughness during hard turning of AISI 4340 steel (69 HRC). Appl Soft Comput 30:279–286
Suresh R et al (2013) State-of-the-art research in machinability of hardened steels. Proc Inst Mech Eng B J Eng Manuf 227(2):191–209
Goel S (2014) A topical review on “The current understanding on the diamond machining of silicon carbide”. J Phys D Appl Phys 47(24):243001
Goel S et al (2015) Diamond machining of silicon: a review of advances in molecular dynamics simulation. Int J Mach Tools Manuf 88:131–164
Zhang Z, Yan J, Kuriyagawa T (2011) Study on tool wear characteristics in diamond turning of reaction-bonded silicon carbide. Int J Adv Manuf Technol 57(1):117–125
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Rashid, W.B., Goel, S., Davim, J.P. et al. Parametric design optimization of hard turning of AISI 4340 steel (69 HRC). Int J Adv Manuf Technol 82, 451–462 (2016). https://doi.org/10.1007/s00170-015-7337-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7337-2