Determination of Optimum Cutting Parameters for Surface Roughness and Tool Flank Wear in Hard Turning by Taguchi Method

Hard turning is a developing technology that offers many potential benefits compared to grinding, which remains the standard finishing process for critical hardened surfaces. The economics of the process must be justified, which requires a better understanding of tool wear patterns, life predictions, cause and effects of defects, also to formulate effective measures to counter the same. Due to the potential advantages of the hard turning process, the present work deals with the optimization of cutting parameters on surface roughness and tool flank wear in finish hard turning of heat treated and tempered HCHCr steel (HRC 48±1) using multilayer coated (TiN/Al2O3/TiN) carbide insert under dry environment. Experiments were conducted on a precision CNC lathe and the influence of cutting parameters was studied using analysis of variance (ANOVA).The Taguchi technique was used to reduce the number of experiments. Based on the main effects plots obtained through ANOVA, optimum level for surface roughness and tool flank wear were chosen from the three levels of cutting parameters considered. Experimental results revealed that feed rate has significantly influenced the surface roughness followed by cutting speed, but surface roughness has no significant effect of the depth of cut. In case of tool flank wear, the influencing factors were found to be cutting speed followed by depth of cut and feed rate. As hard tuning of difficult to cut materials is one among the major machining operations in manufacturing industry, the revelation made in this research would significantly contribute to the cutting parameters’ optimization.

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