Analysis of surface roughness during turning of AISI 52100 hardened alloy steel using minimal cutting fluid application

Abstract

ABSTRACT Surface roughness is an important parameter for machined components. It affects their wear resistance and fatigue life. High-velocity pulsing jet minimal cutting fluid application (MCFA) is one of the emerging technique that helps to minimise the use of cutting fluid and reduce the adverse effects on human health and the environment. In this paper, an attempt was made to study the effects of cutting speed, feed rate and depth of cut on the surface roughness (Ra) in turning of AISI 52100 alloy steel of hardness 58 HRC with multilayer (TiN/TiCN/Al2O3) coated carbide tool insert under MCFA environment. The response surface methodology (RSM) based quadratic regression model for the surface roughness (Ra) was developed with 95% confidence level. The adequacy and validity of the developed model were checked based on P-value, F-value and R2 -value. The analysis of variance (ANOVA) was used to determine the relative significance of cutting parameters and their interactions on the surface roughness (Ra). The result showed that the feed rate had significant effect in reducing the surface roughness followed by cutting speed, whereas depth of cut did not show any significant effect. Experimental data were optimised using the desirability function approach. A good agreement was observed between the predicted output and the experimental result.