Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel

Abstract

In this study, the effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI H13 steel were experimentally investigated. Cubic boron nitrite inserts with two distinct edge preparations and throughhardened AISI H13 steel bars were used. Four-factor (hardness, edge geometry, feed rate and cutting speed) two-level fractional experiments were conducted and statistical analysis of variance was performed. During hard turning experiments, three components of tool forces and roughness of the machined surface were measured. This study shows that the effects of workpiece hardness, cutting edge geometry, feed rate and cutting speed on surface roughness are statistically significant. The effects of twofactor interactions of the edge geometry and the workpiece hardness, the edge geometry and the feed rate, and the cutting speed and feed rate also appeared to be important. Especially honed edge geometry and lower workpiece surface hardness resulted in better surface roughness. Cutting-edge geometry, workpiece hardness and cutting speed are found to be affecting force components. The lower workpiece surface hardness and honed edge geometry resulted in lower tangential and radial forces.

The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools

“…In secondary edge studies, researchers [1,4,[8][9][10][11][12][13][14][15][16], machining ferrous and non-ferrous work materials with carbide, ceramic (PCD and PCBN) and single crystal diamond (SCD) tool inserts, report peak-to-valley roughnesses, e.g. R z , close to kinematic values f 2 / (8r n ) at large feeds, where f is feed, r n is tool nose radius.…”

Identification of Optimum Parameters for MRR on Hard Turning of AISI H13 Steel by using TAGUCHI ANALYSIS and ANOVA

“…Tugrulo zel et al (2004), [2] This paper is focused on the effects of work piece hardness, cutting edge geometry, feed rate and cutting speed on surface roughness are statistically significant. The effects of two factor interactions of the edge geometry and the work piece hardness, the edge geometry and the feed rate, and the cutting speed and feed rate also appeared to be important.…”

Analysis of the variability of cutting processes when many factors are perturbed

“…Again, the AMM project aimed to encourage researchers to delve into the knowledge of the cutting processes to assess reliable models (Ivester and Kennedy, 2004). The goal of the AMM project is to assess the ability of state-of-the-art machining models to make accurate predictions of the behaviour of practical machining operations, based upon the knowledge of machining parameters typically available on a modern industrial shop floor (Ivester et al, 2000(Ivester et al, , 2002Özel et al, 2005Özel et al, , Settineri et al, 2005. In this paper, the philosophy of the project is maintained, but different goals are pursued.…”

“…Nowadays, the simulation of common machining processes is well studied and powerful software can be used to increase the knowledge, test different scenarios and choose the best configuration that guarantee both high performances and savings. Before using complex tools, it is necessary to obtain information from data collection, to explain the behaviour of the cutting performances, when some parameters or conditions vary (Ivester et al, 2000;Özel et al, 2005Özel et al, , Settineri et al, 2005.…”