Effect of Machining Parameters on Tool Wear and Nodal Temperature in Hard Turning of AISI D3 Steel

Bhemuni, Varaprasad; Rao, Ch. Srinivasa; Kondapalli, Siva Prasad

doi:10.4236/oalib.1100627

Cited by 4 publications

(2 citation statements)

References 16 publications

(12 reference statements)

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“…9 In a minor study by taking advantage of CBN inserts in the course of turning of D3 tool steel, Bouchelaghem et al 10 have established an interrelationship between the rate of tool wear, the surface roughness of the machined, the magnitude of cutting forces, and temperature in the machining region. In the latest methodological study, Bhemuni et al 11 divulged that the nodal temperature rise in the cutting region is due to both depth of cut and axial feed, however, depth of cut as well as cutting speed are principally accountable for flank wear during machining of hardened D3 tool steel with a ceramic insert. While Aouici et al 12 proposed the response surface methodology (RSM), as well as a desirability function-based optimization of response characteristics in the machining of heat-treated D3 tool steel with TiN coated hybrid ceramic inserts.…”

Section: Introductionmentioning

confidence: 99%

Analysis and prediction of tool wear in dry turning of hardened D3 steel using hybrid insert: A novel wear map approach

Rath

Panda

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Previously cubic boron nitride (CBN) and ceramic inserts were used for the dry turning of heat-treated D3 tool steel with cutting speed beyond 200 m/min, suffers from severe tool wear and generation of high temperature at the interface. To overcome these shortcomings, a hybrid ceramic insert that is, Al2O3 + Ti (C,N) with coated (TiN) is used in dry turning of D3 tool steel (heat-treated). Use of the hybrid insert with a lower feed rate (0.04 mm/rev) and a minimum depth of cut (0.4 mm) improves the surface quality of the turning process by significantly reducing the tool wear and cutting forces requirement in a cutting speed range of 165– 175 m/min. Even though ceramic tool inserts have high wear resistance at elevated temperatures but it has limited impact strength. So, ceramics is only recommended for shocks and vibration-free high-speed cutting operations of hardened steel under a dry environment. The novelty of this article is the development of a wear map for the analysis and prediction of tool wear. The Scanning electron microscope studies of wear region elucidate that low tool wear that the predominant modes of wear for low tool wear cutting conditions are delamination and abrasion. Besides for higher tool wear the prevailing wear mode is a combination of abrasion as well as adhesion wear. It is perceived that our proposed methodology outperforms the state-of-the-art methods.

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Section: Introductionmentioning

confidence: 99%

Analysis and prediction of tool wear in dry turning of hardened D3 steel using hybrid insert: A novel wear map approach

Rath

Panda

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…A recent methodical by Bhemuni et al. 20 revealed the overall effect of input parameters on the performance characteristics, i.e. temperature at cutting zone and tool life in horizontal turning of hardened AISI D3 steel (having a hardness of 62 HRC) by using a ceramic turning tool.…”

Section: Introductionmentioning

confidence: 99%

Dry turning of AISI D3 steel using a mixed ceramic insert: A study

Rath

Panda

Pal

2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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AISI D3 steel is a new kind of hardened tool steel with excellent wear resistance. This hard material receives wide promotion, investigation, and application in the die manufacturing industries. In the machining of AISI D3 steel, tool wear has a close relationship with the presence of different constituent elements in the workpiece material and cutting conditions. This study reports an improved experimental investigation approach to the analysis of effect of cutting speed, feed rate, and depth of cut on cutting forces, surface roughness, tool wear, and chip morphology in high-speed turning of AISI D3 steel using a hybrid TiN-coated Al2O3 + TiCN mixed ceramic insert. The range of each parameter is set at different levels for the analysis purpose. The experimental observations show that the cutting force is predominantly influenced by the feed rate accompanied by the depth of cut. The predominant factor influencing flank wear is the feed rate accompanied by the depth of cut and cutting speed. Feed rate is one of the dominating factors that influences the surface finish characteristics. The characterization of tool wear and chip morphology was performed by a scanning electron microscope supplied with energy-dispersive X-ray spectroscopy pattern. The results demonstrated that the predominant wear mechanism of the multilayered hybrid-coated tool was flank wear, crater wear, adhesion wear, and abrasive wear.

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Performance Analysis of Hybrid Ceramic Insert in Dry Turning of Hardened Tool Steel

2022

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Effect of Machining Parameters on Tool Wear and Nodal Temperature in Hard Turning of AISI D3 Steel

Cited by 4 publications

References 16 publications

Analysis and prediction of tool wear in dry turning of hardened D3 steel using hybrid insert: A novel wear map approach

Analysis and prediction of tool wear in dry turning of hardened D3 steel using hybrid insert: A novel wear map approach

Dry turning of AISI D3 steel using a mixed ceramic insert: A study

Performance Analysis of Hybrid Ceramic Insert in Dry Turning of Hardened Tool Steel

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