Skip to main content
SpringerLink
Log in

Effect of Tool Material Properties and Cutting Conditions on Machinability of AISI D6 Steel During Hard Turning

  • Research Article - Mechanical Engineering
  • Published:
Arabian Journal for Science and Engineering Aims and scope Submit manuscript

Abstract

Hard turning offers numerous advantages to grinding operation; however, there is a critical need for research to clarify issues related to high cutting forces, high temperatures, and surface roughness to meet the challenges it can offer as an alternate to grinding process. Mathematical models are generated for each response variable (main cutting force, thrust force, cutting temperature, and surface roughness) in terms of actual values of the factors (cutting speed, feed, and tool material) to establish relationships using design expert software for statistical investigation. A 33 full-factorial design with a total of 27 experiments was obtained for parametric analysis and investigation of machinability of AISI D6 tool steel using three different grades of low-content cubic boron nitride (CBN-L) inserts. The parametric analysis study shows that the main cutting force, thrust force, and surface roughness increase with feed. The thrust force and cutting temperature get influenced by tool material properties. It was established that grain size, CBN content, edge geometry, and hardness of the tools affected all the output characteristics. Scanned electron microscopy and energy-dispersive X-ray of the worn tools showed crater wear, chipping, and fracture of cutting edges, while abrasion and diffusion/dissolutions in CBN tools were the wear mechanisms affirmed in this study.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Amini S., Fatemi M.H., Ateli R.: High speed turning of Inconel 718 using ceramic and carbide cutting tools. Arab. J. Sci. Eng. 39, 2323–2330 (2014)

    Article  Google Scholar 

  2. Sharma A., Sharma M.D., Sehgal R.: Experimantal study of machining characteristics of titanium alloy Ti-6Al-4V. Arab. J. Sci. Eng. 39, 3201–3209 (2014)

    Google Scholar 

  3. Ozturk S.: Machinability of stellite-6 coatings with ceramic inserts and tungsten carbide tools. Arab. J. Sci. Eng. 39, 7375–7383 (2014)

    Article  Google Scholar 

  4. Kundra J., Mamalis A.J., Markopoulos A.: Finishing of hardened boreholes: grinding or hard cutting. Mater. Manuf. Process. 19, 979–993 (2004)

    Article  Google Scholar 

  5. Huang Y., Chou Y.K., Liang S.Y.: CBN tool wear in hard turning: a survey on research progresses. Int. J. Adv. Manuf. Technol. 35, 443–453 (2007)

    Article  Google Scholar 

  6. Singh D., Venkateswara P.R.: Optimization of tool geometry and cutting parameters for hard turning materials. Mater. Manuf. Process. 22, 15–21 (2007)

    Article  Google Scholar 

  7. Senthil N., Tamizharasam T.: Effect of tool geometry in turning AISI 1045 steel: experimental Investigation and FEM analysis. Arab. J. Sci. Eng. 39, 4963–4975 (2014)

    Article  Google Scholar 

  8. Trent E.M., Wright P.K.: Metal Cutting. Butterworths Heinemann Ltd., London (2004)

    Google Scholar 

  9. Knuefermann M.M.W., Read R.F.J., Nunn R., Clark I.E., Flemming M.A.: 22 nm Ra surface finish achieved with amborite DBN 45 in ultra presicion turning of hardened steel. Ind. Diam. Rev. 2, 87–92 (2002)

    Google Scholar 

  10. Chou Y.K., Evans C.J., Barash M.M.: Experimental investigation on CBN turning of AISI 51200 steel. J. Mater. Process. Technol. 134, 1–9 (2009)

    Article  Google Scholar 

  11. Qian, L.; Lei, S.; Chen, R.: Finite element analysis of hard turning bearing 201 steel AISI 52100 with varoius inserts. In: ASME Pressure Vessels 202 and Piping Conference. PVP-ICPVT 11-93149, Vancouver, Canada (2006)

  12. Huang Y., Liang S.Y.: Cutting forces modelling considering the effect of tool thermal property application to CBN hard turning. Int. J. Mach. Tools Manuf. 43, 307–315 (2003)

    Article  Google Scholar 

  13. Dogra M., Sharma V.S.: Machinability and surface quality issues in finish turning of hardened steel with coated carbide and CBN tools. Mater. Manuf. Process. 27, 1110–1117 (2012)

    Article  Google Scholar 

  14. Tonshoff H.K., Wobker H.G., Brandt D.: Hard turning influence on workpiece material properties. Trans. NAMRI/SME 23, 215–220 (1995)

    Google Scholar 

  15. Huddle D.: New hard turning tools and techniques offer a cost effective to alternative to grinding. Tool. Prod. Mag. 80, 96–103 (2001)

    Google Scholar 

  16. Gaitonde V.N., Karnik S.R., Figueira L., Davim J.P.: Analysis of machinability during hard turning of cold work tool steel (type: AISI D2). Mater. Manuf. Process. 24, 1373–1382 (2009)

    Article  Google Scholar 

  17. Senthil N., Tamizharasam T., Gobikanna S.: Application of response surface methodology (RSM) and firefly algorithm for optimizing multiple responses. Arab. J. Sci. Eng. 39, 8015–8030 (2014)

    Article  Google Scholar 

  18. Ganeshan H., Kumar G.M.: Optimization of machining techniques in CNC turning centre using genetic algorithm. Arab. J. Sci. Eng. 38, 1529–1538 (2013)

    Article  Google Scholar 

  19. Ekici E., Samatas G., Gulesin M.: Experimental and statistical investigation of the machinability of Al-10% SiC MMC produced by hot pressing method. Arab. J. Sci. Eng. 39, 3289–3298 (2014)

    Article  Google Scholar 

  20. Ota M., Kukino S., Uesaka S., Fukaya T.: Development of SUMIBORON PCBN tools for machining of sintered powder metal alloys and cast iron. SEI Tech. Rev. 59, 61 (2005)

    Google Scholar 

  21. Lehman, L.R.; Gould, J.E.: A design-of-experiments evaluation of resistance spot welding manufacturability part 3: optimization and process robustness studies. In: IBEC 96 Proceedings, Advanced Technologies and Processes, Warren, Michigan, IBEC Ltd (1996)

  22. Thiele J.D., Melkote S.N.: 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, 216–226 (1999)

    Article  Google Scholar 

  23. Quin L., Hossan M.R.: Effect on cutting force in turning hardened tool steels with cubic boron nitride inserts. J. Mater. Process. Technol. 191, 274–278 (2007)

    Article  Google Scholar 

  24. Huang Y., Liang S.Y., George W.: Cutting forces modelling considering the effects of tool thermal properties applicable to CBN hard turning. Int. J. Mach. Tools Manuf. 43, 307–315 (2003)

    Article  Google Scholar 

  25. Ozel T., Hus T.K., Zerne E.: 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, 262–269 (2005)

    Article  Google Scholar 

  26. Abdullah K., Ulvi S.: The effect of chamfer angle of polycrystalline cubic boron nitride cutting tool on the cutting forces and the tool stresses in finishing hard turning of AISI 52100 steel. Mater. Des. 26, 351–356 (2005)

    Article  Google Scholar 

  27. Tonshoff, H.K.; Bussman, W.; Stanske, C.: Requirement of tools and machines when machining hard materials. In: Davis, S.A. (eds.) Proceedings 25th MTDR Conference, Manchester, Macmillan, London, pp. 349–357, 17–18 Sept (1986)

  28. Shaw M.C.: Metal Cutting Principal. Oxford, New York (1984)

    Google Scholar 

  29. Davim J.P.: A note on the determination of optimal cutting conditions for the surface finish obtained in turning using design of experiments. J. Mater. Process. Technol. 116, 305–308 (2001)

    Article  Google Scholar 

  30. Lima J.G., Avilla R.F., Abrao A.M., Faustino M., Davim J.P.: Hard turning AISI 4340 high strength low alloyed steel and AISI D2 cold work steel. J. Mater. Process. Technol. 169, 388–395 (2005)

    Article  Google Scholar 

  31. Chou Y.K., Evans C.J.: Tool wear mechanism in continuous cutting of hardened tool steels. Wear 212, 59–65 (1997)

    Article  Google Scholar 

  32. Rai, G.: The metallurgy of CBN and its wear in high speed machining of ferrous materials. In: Machining of Advanced Materials, Proceedings of the International Conference on Machining of Advanced Materials, Gaithersburg, pp. 501–514, 20–22 July (1993)

Download references

Author information

Authors and Affiliations

  1. National Institute of Technology, Hamirpur, 177005, India

    Manoj Nayak

  2. Department of Mechanical Engineering, FET, MRIU, Faridabad, 121006, India

    Manoj Nayak

  3. Department of Mechanical Engineering, National Institute of Technology, Hamirpur, 177005, India

    Rakesh Sehgal

Authors
  1. Manoj Nayak
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Rakesh Sehgal
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Manoj Nayak.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Nayak, M., Sehgal, R. Effect of Tool Material Properties and Cutting Conditions on Machinability of AISI D6 Steel During Hard Turning. Arab J Sci Eng 40, 1151–1164 (2015). https://doi.org/10.1007/s13369-015-1578-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13369-015-1578-0

Keywords

Search

Navigation