Multi-objective optimization of cutting parameters during sustainable dry hard turning of AISI 52100 steel with newly develop HSN2-coated carbide insert

Abstract

AISI 52100 steel is considerably attracted in making bearings and shafts due to its greater strength and better corrosion immunity. Hard turning with a coated carbide tool has many benefits over grinding operation due to the reduction in processing costs, increment in production rate and post machining improved material properties. In the present study, execution of a new type of coating material, HSN2 with 12 µm thickness on carbide insert by using physical vapor deposition technique for machining hard AISI 52100 steel of hardness 55 HRC is evaluated. Also, the coated carbide insert is characterized by DSC and TGA for thermal and oxidation stability at high temperature. Further, a relationship is built between input process parameters i.e. cutting speed, feed rate and depth of cut with output responses i.e. main cutting, radial and feed forces, maximum flank wear and surface quality of work piece. Statistical design of experimental is used to examine the consequence of cutting parameters on machinability prospects. Also, the regression models are developed to correlate between input process parameters and output responses. Further, the cutting parameters are optimized using response surface method and validated using confirmation tests. From conformation test, it is observed that the percentage error for main cutting force, radial force, feed force, surface roughness and flank wear are 4.3%, 3.33%, 6.8%, 6.2% and 0.05%, respectively. The maximum value of the observed tool wear is 292 µm which is acceptable as per ISO Standard 3685. It is found that the cutting speed is the most effective parameter among all output responses. The machining of AISI 52100 steel having hardness 55 HRC at high speed range of 102–287 m/min with a newly developed coating material HSN2 with 12 µm thickness is the novelty of the present work.