Abstract
The main purpose of this study is to investigate the influence of tool geometry (cutting edge angle, rake angle, and inclination angle) and to optimize tool wear and surface roughness in hard turning of AISI 1055 (52HRC) hardened steel by using TiN coated mixed ceramic inserts. The results show that the inclination angle is the major factor affecting the tool wear and the surface roughness in hard turning. With the increase in negative rake and inclination angles, the tool wear decreases, and the surface roughness increases. However, the surface roughness will decrease when the inclination angle increases to overpass a certain limit. This is a new and significant point in the research of the hard turning process. From this result, the large negative inclination angle (λ = −10°) should be applied to reduce the surface roughness and the tool wear simultaneously. With the optimal cutting tool angles in the research, the hard machining process is improved remarkably with decreases of surface roughness and tool wear 8.3% and 41.3%, respectively in comparison with the standard tool angles. And the proposed tool-post design approach brings an effective method to change the tool insert angles using standard tool-holders to improve hard or other difficult-to-cut materials turning quality.
Highlights
Hard turning is a developing technology to machine parts with high hardness (HRC value 45 and above) such as gears, shafts, bearings as well as other components for advanced industries
Response Surface Design (RSM) is a collection of mathematical and statistical techniques that are useful for the modeling and analysis of problems in which a response of interest is influenced by several variables[25] and response surface methodology (RSM) coupled with Central Composite Design (CCD), desirability function (DF) optimization becomes an effective method to design experiments, develop mathematical model and optimize this response with a moderate number of experiments
A change in cutting edge angle does change the cutting position on the tool nose radius as Figure 3(a) and the change of the rake and inclination angles mainly cause the change of the local inclination angle and the local rake angle respectively at given each point of the tool nose radius cutting edge in hard turning process as Figure 3(b)
Summary
Hard turning is a developing technology to machine parts with high hardness (HRC value 45 and above) such as gears, shafts, bearings as well as other components for advanced industries. For this purpose, many studies have been conducted using different computational methods in modeling and optimizing of the hard turning process such as: Singh and Venkateswara Rao,[2] studied the effect of tool geometry (effective rake angle and nose radius) and cutting conditions (cutting speed and feed rate) on surface roughness during hard turning AISI 52100 steel (58 HRC) with mixed ceramic inserts. The study of Zerti et al.[5] used an application of Taguchi method to optimize cutting parameters (approach angle, tool nose radius, cutting speed, feed rate, and cutting depth) in order to minimize surface roughness, cutting force, and cutting power in dry turning on AISI D3 steel. The result showed that increasing the approach angle, tool nose radius will reduce surface roughness and approach angle is an insignificant contribution on the main cutting force
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