Comparative study on machinability improvement in hard turning using coated and uncoated carbide inserts: part II modeling, multi-response optimization, tool life, and economic aspects

The present study focused on mathematical modeling, multi response optimization, tool life, and economical analysis in finish hard turning of AISI D2 steel ((55 ± 1) HRC) using CVD-coated carbide (TiN/TiCN/Al2O3) and uncoated carbide inserts under dry environmental conditions. Regression methodology and the grey relational approach were implemented for modeling and multi-response optimization, respectively. Comparative economic statistics were carried out for both inserts, and the adequacy of the correlation model was verified. The experimental and predicted values for all responses were very close to each other, implying the significance of the model and indicating that the correlation coefficients were close to unity. The optimal parametric combinations for Al2O3 coated carbide were d1–f1–v2 (depth of cut = 0.1 mm, feed = 0.04 mm/r and cutting speed = 108 m/min), and those for the uncoated tool were d1–(0.1 mm)–f1 (0.04 mm/r)–v1 (63 m/min). The observed tool life for the coated carbide insert was 15 times higher than that for the uncoated carbide insert, considering flank wear criteria of 0.3 mm. The chip volume after machining for the coated carbide insert was 26.14 times higher than that of the uncoated carbide insert and could be better utilized for higher material removal rate. Abrasion, diffusion, notching, chipping, and built-up edge have been observed to be the principal wear mechanisms for tool life estimation. Use of the coated carbide tool reduced machining costs by about 3.55 times compared to the use of the uncoated carbide insert, and provided economic benefits in hard turning.

[1]  Y. Sahin,et al.  Comparison of tool life between ceramic and cubic boron nitride (CBN) cutting tools when machining hardened steels , 2009 .

[2]  Biswanath Doloi,et al.  Optimization of flank wear using Zirconia Toughened Alumina (ZTA) cutting tool: Taguchi method and Regression analysis , 2011 .

[3]  Ashok Kumar Sahoo,et al.  Performance studies of multilayer hard surface coatings (TiN/TiCN/Al2O3/TiN) of indexable carbide inserts in hard machining: Part-II (RSM, grey relational and techno economical approach) , 2013 .

[4]  Sounak Kumar Choudhury,et al.  Influence of machining parameters on forces and surface roughness during finish hard turning of EN 31 steel , 2014 .

[5]  B. B. Biswal,et al.  Comparative Assessment on Machinability Aspects of AISI 4340 Alloy Steel Using Uncoated Carbide and Coated Cermet Inserts During Hard Turning , 2016 .

[6]  Bala Murugan Gopalsamy,et al.  Optimisation of machining parameters for hard machining: grey relational theory approach and ANOVA , 2009 .

[7]  S. K. Choudhury,et al.  Machining of hardened steel—Experimental investigations, performance modeling and cooling techniques: A review , 2015 .

[8]  Ajay P. Malshe,et al.  Tool wear and machining performance of cBN–TiN coated carbide inserts and PCBN compact inserts in turning AISI 4340 hardened steel , 2006 .

[9]  Ashok Kumar Sahoo,et al.  A response surface methodology and desirability approach for predictive modeling and optimization of cutting temperature in machining hardened steel , 2014 .

[10]  S. K. Choudhury,et al.  Effect of work material hardness and cutting parameters on performance of coated carbide tool when turning hardened steel: An optimization approach , 2013 .

[11]  A. Abrão,et al.  Hard turning: AISI 4340 high strength low alloy steel and AISI D2 cold work tool steel , 2005 .

[12]  Salim Belhadi,et al.  Analysis and optimization of hard turning operation using cubic boron nitride tool , 2014 .

[13]  R. Suresh,et al.  Some studies on hard turning of AISI 4340 steel using multilayer coated carbide tool , 2012 .

[14]  J. Paulo Davim,et al.  Machinability investigations in hard turning of AISI D2 cold work tool steel with conventional and wiper ceramic inserts , 2009 .

[15]  Biswanath Doloi,et al.  Predictive modeling of surface roughness in high speed machining of AISI 4340 steel using yttria stabilized zirconia toughened alumina turning insert , 2013 .

[16]  Nouredine Ouelaa,et al.  Analysis and prediction of tool wear, surface roughness and cutting forces in hard turning with CBN tool , 2012 .

[17]  J. I. Nanavati,et al.  Optimisation of machining parameters for turning operations based on response surface methodology , 2013 .

[18]  Tarek Mabrouki,et al.  Modeling and optimization of hard turning of X38CrMoV5-1 steel with CBN tool: Machining parameters effects on flank wear and surface roughness , 2011 .

[19]  Sounak Kumar Choudhury,et al.  Investigations on machinability aspects of hardened AISI 4340 steel at different levels of hardness using coated carbide tools , 2013 .

[20]  Suleyman Neseli,et al.  Optimization of tool geometry parameters for turning operations based on the response surface methodology , 2011 .

[21]  J. Paulo Davim,et al.  Machinability evaluation in hard turning of cold work tool steel (D2) with ceramic tools using statistical techniques , 2007 .

[22]  Miloš Madić,et al.  Modeling and analysis of correlations between cutting parameters and cutting force components in turning AISI 1043 steel using ANN , 2013 .

[23]  J. Paulo Davim,et al.  Comparative evaluation of conventional and wiper ceramic tools on cutting forces, surface roughness, and tool wear in hard turning AISI D2 steel , 2007 .

[24]  Anupam Agrawal,et al.  Prediction of surface roughness during hard turning of AISI 4340 steel (69 HRC) , 2015, Appl. Soft Comput..

[25]  V. N. Gaitonde,et al.  Machinability investigations on hardened AISI 4340 steel using coated carbide insert , 2012 .

[26]  Tarek Mabrouki,et al.  Analysis of surface roughness and cutting force components in hard turning with CBN tool: Prediction model and cutting conditions optimization , 2012 .

[27]  Ali Riza Motorcu,et al.  Surface roughness model in machining hardened steel with cubic boron nitride cutting tool , 2008 .

[28]  M. Yallese,et al.  Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool , 2010 .

[29]  Pardeep Kumar,et al.  Machinability Study on Finish Turning of AISI H13 Hot Working Die Tool Steel With Cubic Boron Nitride (CBN) Cutting Tool Inserts Using Response Surface Methodology (RSM) , 2015 .

[30]  M. Mohanraj,et al.  Optimization of surface roughness, cutting force and tool wear of nitrogen alloyed duplex stainless steel in a dry turning process using Taguchi method , 2014 .

[31]  İlhan Asiltürk,et al.  Determining the effect of cutting parameters on surface roughness in hard turning using the Taguchi method , 2011 .

[32]  Debabrata Dhupal,et al.  Experimental investigation into machinability of hardened AISI 4140 steel using TiN coated ceramic tool , 2015 .

[33]  Prasanta Sahoo,et al.  Fractal dimension modelling of surface profile and optimisation in CNC end milling using Response Surface Method , 2008, Int. J. Manuf. Res..

[34]  Mustafa Günay,et al.  Application of Taguchi method for determining optimum surface roughness in turning of high-alloy white cast iron , 2013 .

[35]  John Edwin Raja Dhas,et al.  Modeling and prediction of machining quality in CNC turning process using intelligent hybrid decision making tools , 2013, Appl. Soft Comput..

[36]  N. R. Dhar,et al.  Modeling of chip–tool interface temperature using response surface methodology and artificial neural network in HPC-assisted turning and tool life investigation , 2017 .