Comparative assessment of two ceramic cutting tools on surface roughness in hard turning of AISI H11 steel: including 2D and 3D surface topography

Khellaf, A.; Aouici, Hamdi; Smaiah, S.; Boutabba, Smail; Yallese, Mohamed Athmane; Elbah, M.

doi:10.1007/s00170-016-9077-3

Cited by 40 publications

(20 citation statements)

References 30 publications

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“…The variable levels of the machining parameters have been selected within the intervals by taking account the recommendations of the manufacturer of the cutting tool (Taegutec ltd.) and supported by previous work of various authors for investigating surface roughness in hard turning (Suresh and Basavarajappa 2014;Meddour et al 2015;Khellaf et al 2016). The parameters and their corresponding levels are illustrated in Table 1.…”

Section: Methodssupporting

confidence: 62%

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Panda

Das

Dhupal

2017

Process Integr Optim Sustain

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The paper addresses the assessment, modeling, and optimization study of surface roughness in finish dry hard turning (FDHT) of AISI 4340 steel with coated ceramic tool by considering the cutting speed, axial feed, depth of cut, and nose radius as machining parameters. Thirty sets of longitudinal turning trials based on central composite (CCD) design of experiments (DOEs) are performed, and response surface methodology (RSM), particle swarm optimization (PSO), and finally, Gilbert's approach are subsequently applied for mathematical modeling, response optimization, tool life estimation, and economic analysis. Additionally, various diagnostic tests have been executed to check the statistical significance and validity, adequacy, effectiveness, and fitness of data of the proposed model using analysis of variance (ANOVA) and Anderson-Darling normal probability test. Results indicated that nose radius and feed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness is considered. The RSM model combined with PSO technique leads to minimum surface roughness value similar to cylindrical grinding of 0.2021 μm, corresponding to optimum process parameters: 220 m/min of cutting speed, 0.05 mm/rev of feed, 0.193 mm of depth of cut, and 1.6 mm of tool nose radius. Finally, under pre-cited optimum machining conditions, tool life was evaluated to perform cost analysis for the economical justification and feasibility of coated ceramic tools in hard turning. The total machining cost per piece is ensued to be lower ($0.34) as a consequence of higher tool life (44 min), reduction in downtime, and enhancement in savings, which finds economical benefits in hard turning. The novelty aspects of the present work are that (i) it demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing coated ceramic tool in hard turning processes considering technological, economical, and ecological aspects, which are helpful and efficient from industrial point of view and (ii) it contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-55 HRC.

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Section: Methodssupporting

confidence: 62%

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Panda

Das

Dhupal

2017

Process Integr Optim Sustain

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“…The RSM is a procedure used to determine the relationship between the independent process parameters with the desired response and exploring the effect of these parameters on responses, [19]. The experimental results of the measurement of the cutting temperature as a function of different cutting parameters are illustrated in the table 4.…”

Section: Response Surface Methodologymentioning

confidence: 99%

“…The mechanical loadings (e.g. cutting force) generally introduce compressive stresses due to contact pressure, whereas thermal loading is generally associated with tensile stresses [18][19][20][21]. By against for initial measurements the stresses in both directions are compressive excepting the interval of depth between 0.7 to 0.8 mm were the residual stress are tensile.…”

Section: Response Surface Methodologymentioning

confidence: 99%

Experimental Investigations to evaluate the effects of cutting parameters on cutting temperature and residual stresses during milling process of the AISI 1045

Abdelkrim

Brabie

Belloufi

et al. 2017

IOP Conf. Ser.: Mater. Sci. Eng.

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Abstract. Today major metal cutting companies in industrial countries, looking to gain time and reduce manufacturing costs while respecting the environment. There are many phenomena which affect the quality and production costs of the product, including cutting efforts, cutting temperature, residual stresses, etc. A better understanding of these phenomena will reduce production costs and maximize productivity. The aim of this work is to analyze the effect of machining conditions (cutting speed, feed speed and cutting depth) on cutting temperature and residual stresses, during the milling operations using the response surface method. A good accuracy between predicted and measured values of the cutting temperature was found, the cutting speed and the depth of cut are parameters whose effect is most sensitive to the residual stresses and the cutting temperature.However, little influence has been registered in the case of an increase of the feed rate. The percentage of error is 4.57%, indicating that the numerical approach can accurately predict the cutting temperature of the AISI 1045.

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“…Larger approach angle produces greater feed force, but less thrust force and increasing the rake angle in the positive direction, the cutting forces are decreased while the cutting temperature increases. Khellaf et al 7 compared surface roughness in turning AISI H11 steel treated at 50 HRC between TiN coated mixed ceramic CC6050 and uncoated mixed ceramic CC650. A mathematical model relating surface roughness and machining parameters such as cutting radius, cutting speed, feed rate, and depth of cut, was developed using response surface methodology (RSM).…”

Section: Introductionmentioning

confidence: 99%

An experimental study on the effect of tool geometry on tool wear and surface roughness in hard turning

Duc

Giang

Dai

et al. 2020

Advances in Mechanical Engineering

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The main purpose of this study is to investigate the influence of tool geometry (cutting edge angle, rake angle, and inclination angle) and to optimize tool wear and surface roughness in hard turning of AISI 1055 (52HRC) hardened steel by using TiN coated mixed ceramic inserts. The results show that the inclination angle is the major factor affecting the tool wear and the surface roughness in hard turning. With the increase in negative rake and inclination angles, the tool wear decreases, and the surface roughness increases. However, the surface roughness will decrease when the inclination angle increases to overpass a certain limit. This is a new and significant point in the research of the hard turning process. From this result, the large negative inclination angle (λ = −10°) should be applied to reduce the surface roughness and the tool wear simultaneously. With the optimal cutting tool angles in the research, the hard machining process is improved remarkably with decreases of surface roughness and tool wear 8.3% and 41.3%, respectively in comparison with the standard tool angles. And the proposed tool-post design approach brings an effective method to change the tool insert angles using standard tool-holders to improve hard or other difficult-to-cut materials turning quality.

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Comparative assessment of two ceramic cutting tools on surface roughness in hard turning of AISI H11 steel: including 2D and 3D surface topography

Cited by 40 publications

References 30 publications

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Experimental Investigations to evaluate the effects of cutting parameters on cutting temperature and residual stresses during milling process of the AISI 1045

An experimental study on the effect of tool geometry on tool wear and surface roughness in hard turning

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