Abstract
This paper investigates the effect of different cutting parameters (cutting speed, feed rate, and depth of cut) on surface integrity defined in terms of surface roughness and microhardness in dry hard turning process. The workpiece material used was hardened alloy steel AISI 52100 and it was machined on a CNC lathe with coated carbide tool under different settings of cutting parameters. Three cutting parameters each at three levels were considered in the study. Central composite design (CCD) of experiment was used to collect experimental data for surface roughness and microhardness. Statistical analysis of variance (ANOVA) was performed to determine significance of the cutting parameters. The results were analysed using an effective procedure of response surface methodology (RSM) to determine optimal values of cutting parameters. Several diagnostic tests were also performed to check the validity of assumptions. The results indicated that feed rate is the dominant factor affecting the surface roughness whereas the cutting speed is found to be the dominant factor affecting the microhardness. Results also revealed that within the range investigated, good surface integrity is achieved when feed rate and depth of cut are near their low levels and cutting speed is at high level. Finally, the optimal cutting parameters and model equations to predict the surface roughness and microhardness are proposed.
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