Abstract
In the present study, an attempt has been made to investigate the effect of cutting parameters (cutting speed, feed rate and depth of cut) on surface roughness in finish hard turning of 42CrMo4 steel using coated mixed ceramics tool AL2O3/Tic which is approximately composed of 70% of Al2O3 and 30%of Tic. The relationship between cutting parameters (cutting speed, feed rate and depth of cut) and machining output variables (surface roughness) through the response surface methodology (RSM) are analysed and modelled. The combined effects of the cutting parameters on machining output variables are investigated while employing the analysis of variance (ANOVA). The quadratic model of RSM associated with response optimization technique and composite desirability was used to find optimum values of machining parameters with respect to objectives (surface roughness). The results show that the feed rate is the dominant contributor to the roughness parameters Ra and Rt accounting for 57.49% and 61.67%, respectively. A quadratic model best describes the variation of surface roughness with major contribution of feed rate, cutting speed and secondary contributions of interaction effect of cutting speed.DOI: http://dx.doi.org/10.5755/j01.mech.18.5.2704
Highlights
Finish hard turning is an emerging machining process which enables manufacturers to machine hardened materials having hardness greater than 45 HRC using a single point polycrystalline cubic boron nitride (PCBN commonly Known as CBN) or ceramic cutting tool without any aid of cutting fluid on a rigid lathe or turning center
Chandiramani and Cook [9] in their investigation on the effect of varying cutting speeds on the surface finish found an intermediate region of deterioration on surface finish due to the formation of built up edge
An analysis of data variance with arithmetic average roughness Ra and with maximum peak-to-valley height Rt was made with the objective of analyzing the influence of cutting speed Vc, feed rate f and depth of cut ap on the total variance of the results
Summary
Finish hard turning is an emerging machining process which enables manufacturers to machine hardened materials having hardness greater than 45 HRC using a single point polycrystalline cubic boron nitride (PCBN commonly Known as CBN) or ceramic cutting tool without any aid of cutting fluid on a rigid lathe or turning center. This process has become a normal practice in industry because it increased productivity and reduced energy consumption [1, 2]. These model equations have been used to develop surface roughness 3D
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