Abstract
<p class="1Body">Wiper inserts have the characteristics of eliminating many grinding operations and achieving an excellent surface. They also improve component quality and roundness compared with grinding. This paper exposes a performance comparative analysis, involving the criteria of surface roughness (R<sub>a</sub>, R<sub>t</sub> and R<sub>z</sub>) during high strength steel’s turning operation, between the conventional and wiper inserts. The main parameters considered in this study are; the speed of cutting (CS), the feed rate (FR), and the cutting depth (DOC). The test plan was carried-out through (128) test specimens divided into two equal sample groups (A and B), each consists of (64) test specimens. Specimens of group (A) and (B) are tested using wiper and conventional inserts respectively. To apply the required testing conditions, a CNC Turning machine equipped with Sinumeric 840-D, was used. The surface roughness was evaluated using a surface roughness tester (Tesa-rugosurf 90- G). The most important parameters affecting the surface roughness are highlighted. Statistical tests used for this study including the analysis of variance (ANOVA) and the response surface methodology (RSM) are presented. The results show the significance of cutting depth and feed rate in the reduction of surface roughness. The machining conditions producing the optimum roughness of the surface, in the experiment range, were investigated using desirability-function-approach for the optimization of multiple-factors of response. The results showed that the quality of surface derived with the wiper carbide insert has significant improvement in comparison to the conventional carbide insert. The maximum improvement of 3.5 times between the wiper insert and conventional insert was achieved at a surfacing speed of 75 meter/min and is limited to 3, 2.5 and 2 times for a surfacing speed of 100, 125 and 150 meter/min, respectively.</p>
Highlights
The machining process of hard turning has drawn increased attention in research and development
The maximum improvement of 3.5 times between the wiper insert and conventional insert was achieved at a surfacing speed of 75 meter/min and is limited to 3, 2.5 and 2 times for a surfacing speed of 100, 125 and 150 meter/min, respectively
This study investigates whether the surface quality derived with the wiper carbide insert exhibits improvement in surface roughness in comparison to the conventional carbide insert
Summary
The machining process of hard turning has drawn increased attention in research and development. Due to the industrial importance of hardened steels, there is a need for advanced technologies in the machining of these materials (Srithar, Palanikumar, & Durgaprasad, 2014), namely, in the development of processes with a higher material removal rate (MRR). Hard turning works on materials by making use of various solid cutting tools. Wiper inserts can eliminate many of the operations in grinding and achieve excellent surface finish. Wipers improve the roundness and overall quality of the component in comparison to grinding. It is estimated that the cutting time can be reduced to half when the feed is doubled; it is possible to achieve twice the number of components within the same time duration (Sandvik, 2014)
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