Surface roughness analysis of greater cutting depths during hard turning

Dilek Murat; Cihat Ensarioglu; Necmi Gursakal; Ali Oral; Mustafa Cemal Cakir

doi:10.3139/120.111074

Artikel

Surface roughness analysis of greater cutting depths during hard turning

Dilek Murat , Cihat Ensarioglu , Necmi Gursakal , Ali Oral und Mustafa Cemal Cakir

Veröffentlicht/Copyright: 28. August 2017

Veröffentlicht von

Veröffentlichen auch Sie bei De Gruyter Brill

Manuskript einreichen Informationen für Autor*innen

Aus der Zeitschrift Materials Testing Band 59 Heft 9

Abstract

Literally, hard machining describes machining of parts having hardness over 45 HRC. Besides its advantages like high metal removal rate, easiness of adapting to complex part geometries, possibility of dry cutting; this operation, which can substitute grinding in most cases, has some disadvantages. One of them is the significant increase of surface roughness due to tool wear even when the tool life limit is not exceeded. In this study, considering hard turning praxes, higher depths of cut (0.5 to 1.0 mm) were examined when dry turning AISI D2 cold work tool steel, through-hardened to 62 HRC. TiN coated mixed ceramic inserts (Al₂O₃ + TiCN) were employed in the operations. Relationship between surface roughness and cutting parameters (cutting speed, feed and depth of cut) was modeled and analyzed using a Box-Behnken response surface methodology (RSM) design. A linear model best described this relationship. Despite the higher depths of cuts, the surface roughness values achieved were comparable to those in grinding operations. Finally, the optimal values of cutting parameters for minimum surface roughness were predicted.

Kurzfassung

Unter Hartdrehen wird wörtlich die Bearbeitung von Werkstoffen mit einer Härte über 45’ verstanden. Neben seinen Vorteilen, wie eine hohe Metallabtragsrate, eine einfache Anpassung von komplexen Geometrien der Teile, der Möglichkeit des Trockendrehens und dass diese Operation das Schleifen in den meisten Fällen ersetzen kann, hat sie auch einige Nachteile. Einer davon besteht in der signifikanten Steigerung der Oberflächenrauheit aufgrund des Werkzeugverschleißes, auch dann, wenn die Werkzeuglebensdauer nicht erreicht wurde. In der diesem Beitrag zugrundeliegenden Studie werden unter Berücksichtigung von Hartdrehpraktiken größere Schnitttiefen (0.5 bis 1.0 mm) untersucht, und zwar beim Drehen des Kaltarbeitsstahles AISI D2, der bis 62’ durchgehärtet wurde. Es wurden TiN-beschichtete, gemischte Keramikeinsätze (Al₂O₃ + TiCN) in den Bearbeitungsgängen verwendet. Das Verhältnis zwischen der Oberflächenrauheit und den Schneidparametern (Schnittgeschwindigkeit, Vorschub und Schnitttiefe) wurde mittels der Box-Behnken Response Surface Methode (RSM) designt und analysiert. Ein lineares Modell beschrieb dieses Verhältnis am besten. Trotz größerer Schnitttiefen waren die erreichten Oberflächenrauheitswerte vergleichbar mit denen bei Schleifprozessen. Schließlich wurden die optimalen Werte der Schneidparameter für die minimale Oberflächenrauheit vorhergesagt.

*Correspondence Address, Asst. Prof. Dilek Murat, Uludag University, Faculty of Economics and Administrative Sciences, 16059, Bursa, Turkey, E-mail: dilekm@uludag.edu.tr

Asst. Prof. Dilek Murat is currently Assistant Professor in the Department of Econometrics of Uludağ University, Bursa, Turkey. She received her BSc, MSc and PhD degrees in Econometrics from the same university in 2003, 2006 and 2013, respectively. Her research interests are design of experiments, six sigma, multivariate statistical snalysis and applied statistics.

Dr. Cihat Ensarioglu is currently a research assistant at the Department of Mechanical Engineering in Uludağ University, Bursa, Turkey. He received his BSc, MSc and PhD degrees in Mechanical Engineering from the same university in 2003, 2007 and 2014, respectively. His research interests are machining, machine tools, materials and production methods.

Prof. Mustafa Cemal Cakir is currently Professor in the Department of Mechanical Engineering of Uludağ University, Bursa, Turkey. He received his BSc degree from the same university in 1982 and he graduated with MSc from Technical University of İstanbul, Turkey in 1984. He received his PhD degree in Mechanical Engineering from University of Bath, UK, in 1989. His research interests are machining, manufacturing automation, CAD/CAM, machine tools, production methods, and design for manufacturability and assembly.

Prof. Ali Oral is currently Professor in the Department of Mechanical Engineering of Balikesir University, Balikesir, Turkey. He received his BSc and MSc degrees from Uludağ University in Mechanical Engineering in 1988, 1991, respectively. He received his PhD degree in Mechanical Engineering from Balikesir University in 1997. His research interests are machining, tool wear, machine tools and CAD/CAM.

Prof. Necmi Gursakal is currently Professor in the Department of Econometrics of Uludağ University, Bursa, Turkey. He received his BSc degree from Bursa Academy of Economics and Commercial Sciences, Turkey, in 1975 and his PhD degree in Statistics from the same academy in 1980. His research interests are design of experiments, social network analysis, complexity and chaos, six sigma, and big data.

References

1 L.Laperrière, G.Reinhart (Eds.): CIRP Encyclopedia of Production Engineering, Springer, Berlin, Germany (2014)10.1007/978-3-642-20617-7Suche in Google Scholar

2 J. P.Davim (Ed.): Machining of Hard Materials, Springer, London, UK (2011)10.1007/978-1-84996-450-0Suche in Google Scholar

3 W.Grzesik: Influence of tool wear on surface roughness in hard turning using differently shaped ceramic tools, Wear265 (2008), No. 3–4, pp. 327–33510.1016/j.wear.2007.11.001Suche in Google Scholar

4 V. N.Gaitonde, S. R.Karnik, L.Figueira, J. P.Davim: Machinability investigations in hard turning of AISI D2 cold work tool steel with conventional and wiper ceramic inserts, International Journal of Refractory Metals and Hard Materials27 (2009), No. 4, pp. 754–76310.1016/j.ijrmhm.2008.12.007Suche in Google Scholar

5 H.Aouici, H.Bouchelaghem, M. A.Yallese, M.Elbah, B.Fnides: Machinability investigation in hard turning of AISI D3 cold work steel with ceramic tool using response surface methodology, International Journal of Advance Manufacturing Technology73 (2014), No. 9–12, pp. 1775–178810.1007/s00170-014-5950-0Suche in Google Scholar

6 B.Sieben, T.Wagner, D.Biermann: Empirical modeling of hard turning of AISI 6150 steel using design and analysis of computer experiments, Production Engineering4 (2010), No. 2–3, pp. 115–12510.1007/s11740-010-0208-7Suche in Google Scholar

7 G.Bartarya, S. K.Choudhury: State of the art in hard turning, International Journal of Machine Tools and Manufacture53 (2012), No. 1, pp. 1–1410.1016/j.ijmachtools.2011.08.019Suche in Google Scholar

8 A.Agrawal, S.Goel, W. B.Rashid, M.Price: Prediction of surface roughness during hard turning of AISI 4340 steel (69 HRC), Applied Soft Computing30 (2015), pp. 279–28610.1016/j.asoc.2015.01.059Suche in Google Scholar

9 Z.Hessainia, A.Belbah, M. A.Yallese, T.Mabrouki, J. F.Rigal: On the prediction of surface roughness in the hard turning based on cutting parameters and tool vibrations, Measurement46 (2013), No. 5, pp. 1671–168110.1016/j.measurement.2012.12.016Suche in Google Scholar

10 M. C.Cakir, C.Ensarioglu, I.Demirayak: Mathematical modeling of surface roughness for evaluating the effects of cutting parameters and coating material, Journal of Material Processing Technology209 (2009), No. 1, pp. 102–10910.1016/j.jmatprotec.2008.01.050Suche in Google Scholar

11 S. K.Shihab, Z. A.Khan, A.Mohammad, A. N.Siddiquee: Optimization of surface integrity in dry hard turning using RSM, Sadhana-Academy Proceedings in Engineering Science39 (2014), No. 5, pp. 1035–105310.1007/s12046-014-0263-4Suche in Google Scholar

12 P. I.Varela, C. S.Rakurty, A. K.Balaji: Surface integrity in hard machining of 300M steel: Effect of cutting-edge geometry on machining induced residual stresses, Procedia CIRP13 (2014), pp. 288–29310.1016/j.procir.2014.04.049Suche in Google Scholar

13 A. K.Sahoo, B.Sahoo: Performance studies of multilayer hard surface coatings (TiN/TiCN/Al₂O₃/TiN) of indexable carbide inserts in hard machining: Part II (RSM, grey relational and techno economical approach), Measurement46 (2013), No. 8, pp. 2868–288410.1016/j.measurement.2012.09.023Suche in Google Scholar

14 D. I.Lalwani, N. K.Mehta, P. K.Jain: Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel, Journal of Materials Processing Technology206 (2008), No. 1–3, pp. 167–17910.1016/j.jmatprotec.2007.12.018Suche in Google Scholar

15 V. N.Gaitonde, S. R.Karnik, L.Figueira, J. P.Davim: Analysis of machinability during hard turning of cold work tool steel (type: AISI D2), Materials and Manufacturing Processes24 (2009), No. 12, pp. 1373–138210.1080/10426910902997415Suche in Google Scholar

16 T.Tamizharasan, T.Selvaraj, A. NoorulHaq: Analysis of tool wear and surface finish in hard turning, The International Journal of Advanced Manufacturing Technology28 (2006), No. 7–8, pp. 671–67910.1007/s00170-004-2411-1Suche in Google Scholar

17 R.Kountanya, I.Al-Zkeri, T.Altan: Effect of tool edge geometry and cutting conditions on experimental and simulated chip morphology in orthogonal hard turning of 100Cr6 steel, Journal of Materials Processing Technology209 (2009), No. 11, pp. 5068–507610.1016/j.jmatprotec.2009.02.011Suche in Google Scholar

18 H.Bouchelaghem, M. A.Yallese, A.Amirat, T.Mabrouki, J. F.Rigal: Experimental investigation and performance analyses of CBN insert in hard turning of cold work tool steel (D3), Machining Science and Technology14 (2010), No. 4, pp. 471–50110.1080/10910344.2010.533621Suche in Google Scholar

19 D.Singh, P. V.Rao: A surface roughness prediction model for hard turning process, The International Journal of Advanced Manufacturing Technology32 (2007), No. 11–12, pp. 1115–112410.1007/s00170-006-0429-2Suche in Google Scholar

20 J. P.Davim, L.Figueira: Machinability evaluation in hard turning of cold work tool steel (D2) with ceramic tools using statistical techniques, Materials & Design28 (2007), No. 4, pp. 1186–119110.1016/j.matdes.2006.01.011Suche in Google Scholar

21 H.Aouici, M. A.Yallese, K.Chaoui, T.Mabrouki, J. F.Rigal: Analysis of surface roughness and cutting force components in hard turning with CBN tool: Prediction model and cutting conditions optimization, Measurement45 (2012), No. 3, pp. 344–35310.1016/j.measurement.2011.11.011Suche in Google Scholar

22 M.Sarikaya, A.Gullu: Taguchi design and response surface methodology based analysis of machining parameters in CNC turning under MQL, Journal of Cleaner Production65 (2014), pp. 604–61610.1016/j.jclepro.2013.08.040Suche in Google Scholar

23 A. I.Khuri, J. A.Cornell: Response Surfaces: Designs and Analyses, 2^nd Ed.CRC Press, Cambridge, UK (1996)Suche in Google Scholar

24 I.Asilturk, H.Akkus: Determining the effect of cutting parameters on surface roughness in hard turning using the Taguchi method, Measurement44 (2011), No. 9, pp. 1697–170410.1016/j.measurement.2011.07.003Suche in Google Scholar

25 N.Senthilkumar, T.Tamizharasan, V.Anandakrishnan: Experimental investigation and performance analysis of cemented carbide inserts of different geometries using Taguchi based grey relational analysis, Measurement58 (2014), pp. 520–53610.1016/j.measurement.2014.09.025Suche in Google Scholar

26 A.Srithar, K.Palanikumar, B.Durgaprasad: Experimental investigation and surface roughness analysis on hard turning of AISI D2 steel using coated carbide insert, Procedia Engineering97 (2014), pp. 72–7710.1016/j.proeng.2014.12.226Suche in Google Scholar

27 A. K.Sahoo, B.Sahoo: Performance studies of multilayer hard surface coatings (TiN/TiCN/Al₂O₃/TiN) of indexable carbide inserts in hard machining: Part I (An experimental approach), Measurement46 (2013), No. 8, pp. 2854–286710.1016/j.measurement.2013.03.024Suche in Google Scholar

28 M.Sirvanc: Design of experiments for quality, Literature Yayıncılık, Turkey (1997) (in Turkish)Suche in Google Scholar

29 N.Gursakal: Six sigma: Customer-oriented management, Nobel Yayın Dağıtım, Turkey (2005) (in Turkish)Suche in Google Scholar

30 D. C.Montgomery: Introduction to Statistical Quality Control, 4^th Ed., John Wiley & Sons, New York, USA (2001)Suche in Google Scholar

31 M.Morris: Design of Experiments: An Introduction Based on Linear Models, 1^st Ed., Chapman and Hall, CRC, Cambridge, UK (2010)Suche in Google Scholar

32 D. C.Montgomery: Design and Analysis of Experiments, 5^th Ed., Wiley, New York, USA (2001)Suche in Google Scholar

Published Online: 2017-08-28

Published in Print: 2017-09-01

Sie haben derzeit keinen Zugang zu diesem Inhalt.

Artikel in diesem Heft

https://doi.org/10.3139/120.111074