Analysis of technological parameters through response surface methodology in machining hardened X38CrMoV5-1 using whisker ceramic tool (Al2O3+SiC)

Abstract

This experimental study is an attempt to model technological parameters such as cutting forces and surface roughness in hard turning of X38CrMoV5-1 hot work tool steel hardened to 50 HRC. This steel is free from tungsten on Cr-Mo-V basis, insensitive to temperature changes and has a high wear resistance. It is employed for the manufacture of helicopter rotor blades and forging dies. The workpiece is machined by a whisker ceramic tool (insert CC670 of chemical composition 75%Al 2 O 3 +25%SiC) under dry conditions. Based on 3 3 full factorial design, a total of 27 tests are carried out. The range of each parameter is set at three different levels, namely low, medium and high. Mathematical models were deduced by applying analysis of variance (ANOVA) and through factor interaction graphs in the response surface methodology (RSM) in order to express the influence degree of each cutting regime element on cutting force components and surface roughness criteria. The results indicate that the depth of cut is the dominant factor affecting cutting force components. The feed rate influences tangential cutting force more than radial and axial forces. The cutting speed affects radial force more than tangential and axial forces. The results also reveal that feed rate is the dominant factor affecting surface roughness, followed by cutting speed. As for the depth of cut, its effect is not very important. These mathematical models would be helpful in selecting cutting variables for optimization of hard cutting process.

Fabrication and Process Optimization of Chinese Fir-Derived SiC Ceramic with High-Performance Friction Properties

“…A Box–Behnken central combination design was employed to investigate the influence of three factors, namely silicon carbide mass ratio, reaction temperature, and adhesive dosage, on the response values of the friction coefficient of the fir-based silicon carbide ceramic material (FSCC) [ 36 , 37 , 38 ]. Seventeen experimental combinations (two parallel replications for each experimental combination) were generated at three levels for each factor.…”

Investigations on the Effect of CNC Dry Hard Turning Process Parameters on Surface Integrity: A Multi-performance Characteristics Optimization

“…Derakhshan and Akbari [10] explored the effects of independent parameters such as hardness of parts and cutting speeds on the surface quality during CNC turning of AISI 4140 alloy steel with CBN tool. Fnides et al [11] investigated the effect of cutting parameters (cutting speed, feed rate and depth of cut) on surface roughness during hard turning of X38CrMoV5-1 hot work tool steel using a whisker ceramic tool under dry condition and found that the feed rate is the dominant factor for affecting surface roughness, followed by cutting speed. Mandal et al [12] used a central composite design (CCD) based on response surface methodology (RSM) to investigate the machinability of zirconia toughened alumina (ZTA) inserts while turning AISI 4340 steel and they found that cutting speed, depth of cut and the quadratic value of cutting speed have significant effect on the surface roughness.…”

Tool life evaluation of cutting materials in hard turning of AISI H11

“…The analysis of variance ANOVA is a computational technique that enables the estimation of the relative contributions of each of the control factors to the overall measured response. RSM is a collection of mathematical and statistical techniques that are useful for the modelling and analysis of problems in which response of interest is influenced by several variables and the objective is to optimize the response [8][9][10] ].…”