Abstract
Now-a-days due to growing demand of high precision components to attain high performances, hardened steels with hardness above 45HRC have numerous applications in automotive gear, machine tool and die industry because of their superior characteristics (high thermal stability, high indentation resistance, high abrasiveness, low ductility and high value of hardness to modulus of elasticity ratio). For this, higher tool life of cutting inserts cryogenic treatment is considered as the most prominent method but no substantial researches have been found concerning the impact of cryogenic treatment on cermet inserts, especially in turning of hardened steels. Therefore, in the present experimental investigation, the comparative assessment of various responses such as cutting force, flank wear, crater wear, chip morphology and surface roughness were carried out during machining of hardened steel with both untreated and cryo-treated cermet inserts under dry cutting condition. Lastly, the input variables were optimized using Response Surface Methodology (RSM) to evaluate the tool life for the economic analysis. The experimental result demonstrated that the uncoated deep cryo-treated with tempered cermet insert delivered better results in comparison to other cermet inserts. According to cost analysis, uncoated and deep cryo-treated with tempered cermet insert was found to be the most cost saving among other cermet inserts at the optimum cutting condition.
Highlights
Quality, productivity and economic aspects of any machining process are influenced by tool life to a great extent
The tool life is advisably influenced by the generation of high temperature at the tool-work and tool-chip interfaces during hard machining
Various methodologies have been proposed by number of researchers and scientists for the enhancement of tool life, such as coating, heat treatment, application of divergent coolants, use of different types of tool geometries and cryogenic treatment
Summary
Productivity and economic aspects of any machining process are influenced by tool life to a great extent. The tool life is advisably influenced by the generation of high temperature at the tool-work and tool-chip interfaces during hard machining. In order to sustain at such high temperature hardness and wear resistance of the tool material must be high enough. Due to the abrasion of cutting edge and rapid progressive wear on the rake and flank surfaces, the machining characteristics may be severely hampered. Various methodologies have been proposed by number of researchers and scientists for the enhancement of tool life, such as coating, heat treatment, application of divergent coolants, use of different types of tool geometries and cryogenic treatment. Over the last few years, cryogenic treatment has been put through extensively by
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