Analysis and modeling of surface roughness based on cutting parameters and tool nose radius in turning of AISI D2 steel using CBN tool

Abstract

Surface roughness of components having hardness above 45 HRC (Rockwell hardness) like bearings, dies, tools etc. draws specific attention during the turning process. Analysis of surface roughness is presented by many researchers based on cutting conditions during hard turning. In this paper, analysis of surface roughness of AISI D2 steel in hard turning with CBN (cubic boron nitride) tools is performed based on variables like cutting speed, feed and nose radius at a constant depth of cut. Variation of feed affects surface roughness most significantly followed by cutting speed and tool nose radius. Prediction of surface roughness considering simultaneous effect of cutting parameters and tool geometry is very difficult. Here, a mathematical model is developed based on simultaneous effect of feed, cutting speed and nose radius. Moreover, developed model is validated using different sets of cutting conditions and found in close agreement with experimental results.