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Study of surface roughness and flank wear in hard turning of AISI 4140 steel with coated ceramic inserts

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Abstract

This experimental investigation deals with dry hard turning of AISI 4140 steel using PVD-TiN coated Al2O3+TiCN mixed ceramic inserts. The combined effect of cutting parameters (cutting speed, feed and depth of cut) on performance characteristics such as surface roughness and flank wear is explored by Full factorial design (FFD) and analysis of variance (ANOVA). The results show that feed is the principal cutting parameter influencing surface roughness, followed by cutting speed. However, flank wear is affected by the cutting speed and interaction of feed-depth of cut, although depth of cut has not been found statistically significant, but flank wear is an increasing function of depth of cut. Observations are made on the machined surface, and worn tool by Scanning electron microscope (SEM) to establish the process. Abrasion was the major wear mechanism found during hard turning within the studied range. The effect of tool wear on surface roughness was also studied. The experimental data were analyzed to predict the optimal range of surface roughness and flank wear. Based on Response surface methodology (RSM), mathematical models were developed for surface roughness (Ra) and flank wear (VB) with 95% confidence level. Finally, under optimum cutting conditions (obtained by response optimization technique), tool life was evaluated to perform cost analysis for justifying the economic viability of coated ceramic inserts in hard turning. The estimated machining cost per part for TiN coated ceramic was found to be lower (Rs. 12.31) because of higher tool life (51 min), which results in the reduction of downtime and increase in savings.

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Authors and Affiliations

  1. Department of Manufacturing Engineering, National Institute of Technology, 831014, Jharkhand, Jamshedpur, India

    Sudhansu Ranjan Das & Amaresh Kumar

  2. Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, Odisha, 768018, India

    Debabrata Dhupal

Authors
  1. Sudhansu Ranjan Das
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  2. Debabrata Dhupal
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  3. Amaresh Kumar
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Correspondence to Sudhansu Ranjan Das.

Additional information

Recommended by Associate Editor Jihong Hwang

Sudhansu Ranjan Das is a Ph.D. student at the Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur, India doing research on the machining of hardened steel. He received his M.Tech. in Mechanical Engineering in 2010 from KIIT University Bhubaneswar, India.

Debabrata Dhupal is a Professor in the Department of Production Engineering, Veer Surendra Sai University of Technology (VSSUT), Burla, India. He received his Ph.D. in Production Engineering from Jadavpur University, Kolkata, India. His research areas of interest include Micromachining, Advance Manufacturing Process, Rapid Prototyping & Non-traditional machining and Metal Cutting.

Amaresh Kumar is an Associate Professor in the Department of Manufacturing Engineering, National Institute of Technology (NIT), Jamshedpur, India. He received his Ph.D. in Production Engineering from Jadavpur University, Kolkata, India. His research interests include supply chain management, computer integrated manufacturing, machining process modelling, optimization, analysis and prediction.

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Das, S.R., Dhupal, D. & Kumar, A. Study of surface roughness and flank wear in hard turning of AISI 4140 steel with coated ceramic inserts. J Mech Sci Technol 29, 4329–4340 (2015). https://doi.org/10.1007/s12206-015-0931-2

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  • DOI: https://doi.org/10.1007/s12206-015-0931-2

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