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Hard turning is a profitable alternative to finish grinding. The ultimate aim of hard turning is to remove work piece material in a single cut rather than a lengthy grinding operation in order to reduce processing time, production cost, surface roughness, and setup time, and to remain competitive. In recent years, interrupted hard turning, which is the process of turning hardened parts with areas of interrupted surfaces, has also been encouraged. The process of hard turning offers many potential benefits compared to the conventional grinding operation. Additionally, tool wear, tool life, quality of surface turned, and amount of material removed are also predicted. In this analysis, 18 different machining conditions, with three different grades of polycrystalline cubic boron nitride (PCBN), cutting tool are considered. This paper describes the various characteristics in terms of component quality, tool life, tool wear, effects of individual parameters on tool life and material removal, and economics of operation. The newer solution, a hard turning operation, is performed on a lathe. In this study, the PCBN tool inserts are used with a WIDAX PT GNR 2525 M16 tool holder. The hardened material selected for hard turning is commercially available engine crank pin material.Keywords Hard turning · DOE · Material removal rate · Signal-to-noise ratio · Tool life · Validation IntroductionNormally, the hard turning operation is performed on materials having hardness values over 45 HRC in "C" Scale of hardness tester [1]. The polycrystalline cubic boron nitride (PCBN) tools used for hard turning are broadly classified as low-content T. Tamizharasan · T. Selvaraj · A. Noorul Haq (u)

In this research work an attempt has been made to minimize flank wear of uncoated carbide inserts while machining AISI 1045 steel by finite element analysis. Tool wear is the predominant factor that causes poor surface finish and is responsible for the dimensional accuracy of the machined surface. The quality of component produced decides the effectiveness and competitiveness of any manufacturing industry. In this analysis, the effect of tool geometries on performance measures of flank wear, surface roughness and cutting forces generated are evaluated. Three levels of cutting insert shape, relief angle and nose radius are chosen. Taguchi's Design of experiment (DOE) is used to design the experiments. For three parameters and three levels a suitable L 9 Orthogonal array is selected. Based on the designed experiment, simulation analysis is carried out using DEFORM-3D, a machining simulation and analysis software and the output quality characteristics are analysed by statistical techniques like Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA). A validation finite element simulation is conducted with the obtained optimum tool geometry, which is also verified experimentally. It is observed that the performance of the determined tool geometry provides satisfactory results.

Effect of turning parameters on chip generation during machining aluminum composite is studied in this work. Turning of Al-4%Cu-7.5%SiC composite material prepared through powder metallurgy procedure was chosen as the workpiece, machined using uncoated carbide insert TNMG 120404. Chips produced during machining were studied by measuring the thickness and were used along with uncut chip thickness to determine the chip thickness ratio. 99.85% pure aluminum was added with 4% volume fractions of copper and with silicon carbide particulates of 7.5%. To visualize the distribution of reinforcement phases in matrix, scanning electron microscope is used. Taguchi's methodology of design of experiments was adopted for designing a L 9 (Latin square) orthogonal array for experimental investigation, and from analysis of variance, cutting speed influencing the formation of chip by 64.13%, continuing with depth of cut by 35.26%, was identified. Confirmation test accomplished with ideal conditions produces a better chip condition.

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