The aim of this study is to evaluate the impact of factors such as cutting speed, feed rate, and depth of cut on surface roughness and Material Removed Rate (MRR) when machining in dry face milling AISI 1040 steel with coated carbide inserts GC1030 using the response surface methodology (RSM). For this purpose, a number of machining experiments based on statistical three-factor and three-level factorial experiment designs, completed (L27) with a statistical analysis of variance (ANOVA), were performed in order to develop mathematical models and to identify the significant factors of these technological parameters. Multi-objective optimization procedure for minimizing Ra, Ry and Rz and maximizing MRR using desirability approach has been also implementented. The current study was also carried out to investigate the tool life of the inserts. The models found the relationship between the cutting parameters (Vc, fz and ap) and the studied technological parameters. It has been found that the cutting speed was the most affecting surface roughness which is due to the geometry of the insert which has a scraping edge and enables to obtain low roughness even at important feed rate, followed by the feed rate and the depth of cut at the end. The optimal combination of cutting parameters were cutting speed of 314 m/min, feed rate of 0.16 mm/tooth and depth of cut of 0.6 mm with a composite desirability of 0.924.
The aim of this experimental study is to evaluate the tool life of each cutting material used in dry hard turning of AISI Hll, treated at 50 HRC. This steel is intended for hot work, is free from tungsten on CrMoV basis, insensitive to temperature changes and has a high wear resistance. It is employed for the manufacture of the moulds and inserts, module matrices of car doors and helicopter rotor blades. The tests of straight turning were carried out using the following cutting materials: carbides (H13A and GC3015), ceramics (mixed CC650 and reinforced CC670) and cermets (CT5015 and GC1525). Experimental results enable us to study the influence of machining time on flank wear VB of these cutting materials and to determine their lifespan for this cutting regime (depth of cut a^ = 0.15 mm, feed rate/= 0.08 mm/rev and cutting speed K^ = 120 m/min). It arises that mixed ceramic (insert CC650) is more resistant to wear than cutting materials. Its tool life is 49 min and consequently, it is the most powerful.
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