Surface finish generated in turning of medium carbon steel parts using conventional and adhesive bonded tools

Abstract

Abstract Cutting tool technology is fully developed to the maximum extent. Still, an alternate cutting tool material is gaining popularity against conventional tool materials over the past few years. A bonded tool with Ana bond 220, as an adhesive is being searched for its feasibility. This paper reports some important characteristics of the surface roughness produced in the turning of a medium carbon Steel using adhesive bonded tools and conventional brazed tools. Experimentation is performed and surface roughnesses are measured. A statistical mathematical model of the process is obtained by using factorial experimentation, regression analysis and movement along the gradient. The coefficient of correlation R values for the surface roughness for all the models represented are in the range of 0.965–0.992, indicating the better correlation between the experimental and predicted values. A function approximation method is used to train the neural network with different optimization algorithms, transfer functions and topology. Overall neural network performed very well with coefficient of determination R2 as 0.977 and 0.978 respectively for the adhesive bonded tools and brazed tools. Finite element analysis is successfully used as an alternate tool to comprehensively represent the performance of adhesive bonded tools in the metal cutting operation. The surface roughness of the machined components produced by the adhesive bonded tools are significantly less than that with brazed tools and hence adhesive bonded tools is a better alternative with distinct advantages in the field of tool manufacturing.