Effect of Tool Vibration on Flank Wear and Surface Roughness During High-Speed Machining of 1040 Steel

Abstract

In recent years, the tool condition monitoring mechanism is necessary for analyzing the failure of the cutting tools in production practices. In a machining environment, steady and catastrophic failures of a tool are general faults associated with a machining process. The relationship between surface roughness, tool wear and vibration is explored during high-speed dry machining by using main input factor. L27 numbers of trials were performed in a CNC lathe with uncoated carbide CNMG120408 tool and alloy steel AISI 1040 workpiece. The predictable model is capable of expecting surface roughness (Ra), tool wear (VBc), and vibration of amplitude using observed data when turning alloy steel. The vibration was recorded only in the turning direction with a uniaxial accelerometer. Additionally, tool flank wear and finished work surface roughness are measured at various combinations of parameters. The outcomes of the work show that the axial feed rate is the main effective turning variable that influences surface roughness largely (91.97%). Optimization of turning process variables plays a significant role in turning to develop quality, manufacturing production rate and decrease production price. In this analysis, an advanced weighted principal component analysis strategy was initiated to optimize process variables in turning of 1040 alloy steel and the optimum relation was found to be d3 (0.5 mm)–f1 (0.06 mm/rev)–v3 (300 m/min). Higher depth of cutting along with largest cutting speed confirms the larger production rate which is desirable for industrial concern. Also, at the optimal setting, the excellent finish of surface with low wear and low acceleration is noticed with an improved S/N ratio of CQL from initial setting. However, the current work presented a better co-relation between tool vibrations, tool wear, and test surface finish which will be beneficial for the industrial uses.