Comparative study on cutting performance of plain and coated carbide inserts in CNC turning of EN9 steel

Abstract

The present work deals with comparative study on cutting performance of plain carbide and coated carbide inserts in turning of EN9 steel. The design of experiments (DOE) was done using response surface methodology (RSM) technique. The cutting parameters were spindle speed, feed and depth of cut (DOC). The combined interactions of cutting parameters on surface roughness, flank wear and crater wear were analyzed. The crater and flank wear were observed using machine vision system. This work is concentrated on building up a mathematical relation between cutting parameters and output responses. Analysis of variance (ANOVA) was used for checking the adequacy of the model. The relation between input factors and the response parameters are determined using a cubic regression model. The optimization was done using desirability ramp plots. The main motive behind this research is to compare the performance of plain and coated carbide tool and analyzing which tool performs better and to optimize the cutting parameters for high quality and cost reduction. It was concluded from this research that at optimized speed, feed and DOC the coated carbide tool is suitable for turning of EN9 steel. The tool wear observed on coated carbide tool was less than plain carbide tool. The coated carbide tool showed a slight improvement in results as compared to the plain carbide tool.

Experimental tool life and wear analysis of different thickness pecvd TiAlSiN nanocoated cutting tool inserts

“…In the coating range of 5–8 µm, the wear is low due to high-density coating with bonding strength. 26…”

“…The equation ±0.25emtα/2 (n−1) for n-1 = 9df from ‘t’ distribution 0.05 −8df 23,26 with a value 2.262,Sample mean, Tfalse¯ Variance Population standard deviation σ=20.52…”

“…13,18 The lower flank wear acquired in the value of 5.32, 6.56, 8.21 µm it's due to the high dense bonding of the nano-coated cutting tool inserts. 7,26…”

“…In the coating range of 5-8 µm, the wear is low due to high-density coating with bonding strength. 26 Figure 7 (b) represents the surface plots diagrams showing the relationship among wear (mm), tool hardness (HV) and coating thickness (µm) of cutting tool inserts. It is seen in Figure 7 (b) the tool hardness value of 2400 HV to 2440 HV is a smooth curve with higher peaks that indicates lesser wear.…”

“…To find the unknown mean of tool life. 23,41 The equation ± t α/2(n−1) for n-1 = 9df from 't' distribution 0.05 −8df 23,26 with a value 2.262,Sample mean, T…”